NC0024201_Annual Report_20150223

.av K e k P.O.Box 308
�qA 1000 Jackson Street
o Roanoke Rapids,NC 27870
x M,5 Roanoke Rapids Sanitary District [phone]
Fax: [phone]
/..,?, D,s,,ci- www.rrsd.org
liir February 23,2015 CERTIFIED MAIL
RETURN RECEIPT REQUESTED
RECEIVED/DENR/D1WIR
MAR 0 4 !(i15
North Carolina Division of Water Quality
Water Quality
NPDES Section
Permitting Sectior
1617 Mail Service Center
Raleigh,N. C. 27699-1617
Re: 2014 System Performance Annual Report
NPDES#NC0024201
NPDES#WQC00027
NCG 110000
Dear Sir:
Enclosed please find three(3)copies of the District's System Performance Annual Report.
This report is submitted to meet the requirements of the NCDENR/DWQ policy to promote
public oversight of system performance for reduction and elimination of sanitary sewer
overflows (SSO's)from wastewater treatment works and sewer collection systems.
If these documents should be provided to additional DWQ personnel; or if additional
information is required,please contact me.
Very truly yours,
Erat, ----01.-----L----
R.
Danieley Bro , P.E.
Chief Executive Officer
Enclosures
Cc: Gregg Camp
Gregg Wilson
File
c.\documents and setungskniblmy&moneys\npdes pertnHHC I4_srs performance ami report In dot. Page:
1/1

ANNUAL PERFORMANCE REPORT 2014 RECEIVEDIDENRIDWR
ROANOKE RAPIDS SANITARY DISTRICT MAR 0 4 2015
Water Quality
GENERAL INFORMATION Permitting Sectior
A. Regulated entity: Roanoke Rapids Sanitary District,Collection Systems(C.S.)and
Wastewater Treatment Plant(WWTP)
B. Responsible entity: Roanoke Rapids Sanitary District,Dan Brown,CEO
C. Person in charge/contact
1. C.S.:Gregg Wilson, Supervisor
David Warren Scott,Operator in Responsible Charge(ORC)
Eric Wes Deaton,Backup Operator in Responsible Charge
Roanoke Rapids Sanitary District,Distribution&Collection
PO Box 308
Roanoke Rapids,NC 27870
Phone: [phone]
2. WWTP: Gregg Camp,Operator in Responsible Charge(ORC)
Roanoke Rapids Sanitary District,WWTP
135 Aqueduct Road
Weldon,NC 27890
Phone: [phone]
D. Applicable Permit(s)
1. C.S.: North Carolina Environmental Management Commission System-wide Wastewater
Collection System Permit No.WQCS00027
2. WWTP: NPDES NC0024201
Land Application(LA.):WQ0001989
Stormwater(General): NCGI 10000
E. Description of C.S.:
The collection system consists of approximately 130 miles of sewer lines. The sewer lines within
Roanoke Rapids,Gaston and all sub-divisions,which connect to the two main Interceptors,range in size
from 8"to 12". There are two main Interceptors transporting wastewater to the WWTP.
The Roanoke River Interceptor collects wastewater from basins located on the north side of Roanoke
Rapids. The Gaston and Northampton basins are included in this service area. The Interceptor begins
just west of NC 48 in Roanoke Rapids. There are 3 primary basin pump stations and 2 secondary pump
stations along the route. Pipe sizes for the Interceptor ranges from 18"to 30".
The Chockoyotte Creek Interceptor handles the south side of Roanoke Rapids and three sub-divisions,
Lake View Park, Greenbriar and Lincoln Heights, outside the Roanoke Rapids city limits. The
Interceptor begins east of Zoo Road. There is one primary basin pump station along the route. Pipe
size ranges from 12"to 30".
The system has six sewer lift stations. Three stations are located in the Gaston, NC system. One of
these serves a Northampton County School, one serves the Chowan Housing Projects and the other
station pumps all flows from Northampton County across the NC 48 Bridge crossing the Roanoke River
to the Roanoke River Interceptor. The remaining three pump stations are located within the Roanoke
Rapids system. Two of the stations, Belmont and Poplar Springs, discharge to the Roanoke River
Interceptor while the Greenbriar Pump Station discharges to the Chockyotte Creek Outfall.

F. Description of WWTP:
The wastewater treatment plant is rated at 8.34 million gallons per day (MGD). Peak flow is rated at
12.5 MGD.
Treatment processes at the wastewater plant include grit and rag removal. This is followed by primary
clarification,trickling filter biological secondary treatment,activated solids treatment,secondary
clarification,final effluent chlorination/dechlorination processes,and final pH adjustment.
During these processes solids are removed from two locations. Primary clarification removes settleable
solids from incoming wastewater to an anaerobic digestion unit. Here the solids, in the absence of
oxygen,receive pH adjustment,mixing,and heating to produce a stabilized material. Once the solids are
stable,excess water is decanted and returned to the plant for further treatment. The stabilized,thickened
solids are treated with lime for odor control then removed to a holding tank to await land application.
Secondary clarification removes solids from the activated solids process. Here, solids in the presence of
oxygen, ph control, and mixing, accumulate in excess. They are removed, chemically stabilized, and
added to a holding facility. All stabilized solids are analyzed and land applied according to their nutrient
value,ceiling and accumulative requirements.
There are two pumping stations in the wastewater plant distributing wastewater into and through the
plant. Of these two pump stations, one has the capacity to pump 20 MGD and the other 27 MGD
respectively. Also,to aid these two pump stations; a storm water pump station has been installed. This
station intercepts rainwater,an unnecessary load to the treatment plant,and removes it before entry to the
plant. It has the capacity to pump 11.5 MGD. In conjunction to these two pump stations there is one
pump station with capacity of 21 MGD to remove treated flows from the plant in the event of high river
levels preventing normal gravity flow discharge. Various others pumps and mixers are located
throughout the plant for process control.
II. PERFORMANCE
A. Description of overall 12 month performance,noting highlights and deficiencies:
1. C.S.:
The Roanoke Rapids Sanitary District's collection system received its inaugural permit in 2001
under the North Carolina Environmental Management Commission Department of Environment and
Natural Resources system wide wastewater collection system-permitting program.
The performance of the system in 2014 was good.
The Fat, Oil and Grease (FOG) program initiated in 1995 has been a good tool in preventing
Sanitary Sewer Overflows (SSO's). We also have a fulltime employee for the FOG Program who
specifies type and capacity of grease traps on an individual basis for all developments,maintains all
records and inspects all grease traps. He also educates all restaurants and high density residential
housing about grease and how it affects our sewer lines. The use of local newspaper for FOG
program educational ads and the distribution of brochures to restaurants and fast food businesses
have also been effective. Maintenance of records and inspection of grease traps is an ongoing
measure to prevent SSO's.
Preventive Maintenance of at least 30 hours a week cleaning sewer mains has also been an effective
tool in reducing sewer backups and overflows. In 2014, District forces continued proactively
cleaning the mains of high density residential housing prior to major holidays to prevent any grease
related spills. The use of degreasers in pump stations on a regular schedule has proven to be very
effective in preventing lift station down time. Also all pumping stations are checked and cleaned a
minimum of once weekly.
The SCADA system that monitors all lift station 24 hours a day, 365 days a year has prevented lift
station overflows. In addition, each lift station is equipped with emergency generators on site to
-2-

prevent overflows from power outages, except Poplar lift station. In the event we have rain or
outages predicted,a portable generator is placed at the lift station in case it is needed.
There were 22 reportable spills in 2014 of the collection system. Most of these spills
were from very severe rain events that happened in a short period of time. The District
employees were very diligent in getting these spills cleaned up and limed and back in
proper operation. C.Description of any known environmental impacts of violations.
2. WWTP:
Overall performance for 2014 was good. There were 4 NPDES permit limits violations.There were
no monitoring or reporting violations.
Under the current permit,the District has a weekly effluent total suspended solids(TSS)limit of 45
mg/1 (milligrams per liter or parts per million) and a monthly limit of 30 mg/l. Also a weekly
carbonaceous biochemical oxygen demand (CBOD) limit of 37.5 mg/1 and a monthly limit of 25
mg/1. These two samples are composite collected. They are collected over a twenty four hour
period and on a flow proportional basis. The higher the flow, the more sample collected and
conversely,the lower the flow, less sample is collected. The yearly average for TSS was 19.0 mg/1
and CBOD was 4.9 mg/l. Using yearly average influent values for the same parameters this
calculates to a 91.7%and 97.5% removal rate respectively. The permit requirement is 85%.
The permit also contains daily maximum residual chlorine of 50 ug/1(micrograms per
liter or parts per billion). Also permitted is pH. It must be maintained between 6 and 9
units. These two samples are grab or instantaneously collected.
Current plant capacity is 8.34 million gallons per day(MGD)with a peak flow of 12.5 MGD. For
2014 the yearly average low flow was 2.8 MGD with minimum of 2.3 MGD. The yearly average
high flow was 8.6 MGD with a maximum of 15.2 MGD. The yearly average total flow was 4.0
MGD or 48.0% of the plant capacity. This is an increase of 400,000 gallons per day. Rain can
affect flows by inflow and infiltration. In 2014, 64.2" of rain was recorded at the wastewater plant.
The previous year 51.1"was recorded.This is an increase of 13.1"from the previous year.
The District is keenly aware of and has been very responsive to increasing environmental awareness.
House Bill 1160,Clean Water Act of 1999,ratified by the North Carolina General Assembly on July
20`s and signed into law July 21't by the governor,has heightened this awareness. This bill codified
as Chapter 329 session laws became effective October 1999.
In response the District has maintained staff, critical parts inventory, equipment inventory, made
plans to better address extreme conditions, upgraded critical equipment, planned back up or
alternative operations, and requested better responsiveness from sub-contractors. Responses are
continuous and increasing.
In 2014,the District continued to be very active in maintenance issues and concerns. The WWTP
spent in excess of $1,130,000 on maintenance and repairs to equipment, supplies and materials
necessary to operate equipment, sustenance of building and grounds, and capitAli7ed monies to
replace and upgrade equipment.
Some of the repairs,upgrades,or replacements in 2014 include the following. •
Influent Diversion Box. The influent diversion box is the first area of the wastewater process. The
open air collection pit is where the two main interceptors bring all the wastewater in the District's
system to the wastewater plant. A 30" line, Roanoke River, and a 36" line, Chockyotte, meet and
blend at this location. From this point they are piped to the first treatment process or preliminary
station consisting of rag and grit removal. The diversion has two slide gate valves. The influent gate
when open allows all flow from the Chockyotte and Roanoke River lines into the treatment
processes of the plant. Occasionally it must be closed to stop flow into the plant for downstream
equipment repairs. At this time all the flow is pumped to storage and returned to the plant after
repairs. This pump is also used to pump high flows from rains to storage. The pump is 12"and has
some age on it. Even though rebuilt once years ago it has lost efficiency. Due to its age, parts
-3-

needed for repair are difficult if not available at all. To remedy this situation another 12"inch pump
at the effluent for emergency pumping which is basically not used, was switched with the older
pump. The newer pump is now located at the influent diversion box and the older pump at the
basically not used effluent pump location. To accomplish this some additional concrete padding had
to be installed. An additional protective shed was set up. Additional electrical work was done to
provide lighting and battery charger capability. New suction and discharge piping was required for
the pump relocations. A crane was used to relocate the pumps and the diesel fuel tanks. The storage
tanks where the incoming wastewater also underwent some improvements. The tank was retrofitted
with permanent piping to make removal easier. This same was done to the treatment process that
receives the pumped water. In addition, two pumps, one portable and one permanently mounted
were set up at the removal tank also to make wastewater return to the plant treatment processes
easier.
Acid Feed System. Located at the beginning of the treatment process is an acid feed system. It is
located there in the event high pH's enter the plant. There is local and remote monitoring located at
the location to alert personnel as soon as possible of a high pH episode. High pH's can cause
damage to the operations of the plant. High pH' can also cause permit violation. The wastewater
plant is permitted to keep pH's below nine at the discharge of its effluent. Sulfuric acid, 78%is the
chemical used to lower pH's. The old feed system was not functional. The old acid had gone bad
and was removed to a recycling facility. The storage tank which was in poor condition had been
dismantled. And the feed system was inoperable. The only remnant of the old system was the
containment area and the acid tank support base that was severely deteriorated. This left the
wastewater plant vulnerable to high pH's. To remedy this situation a new system was budgeted.
The old containment and tank base were removed. The area had to be graded for the setup of the
new acid feed system. A new containment,tank base,tank,tank housing and feed system were put
back on line. To finish the project a tank fill line was installed. After installing the tank it was filled
with water to check for leaks and functionality. All appeared fine so the water was drained and the
first order of acid was made to fill the tank. The plant is now protected in the event high pH's enter
the plant. The high pH's can now be neutralized with the addition of acid.
Rotamat. The Rotamat is the first piece of equipment in the wastewater process. It removes rags,
plastics, paper, or other non-organic material before they can enter other downstream processes.
This is important to keep this material from clogging pipes,binding pumps and mixers, and causing
damage to other equipment. Flow enters a basket area. As materials build up in the basket area, a
sweeper arm comes on to remove the built up items. The sweeper passes through a comb which
causes the material to be dropped into a screw auger for removal from the wastewater flow. The
Rotamat is controlled by an ultrasonic level indicator. When flows back up and rise in the channel
where the equipment is located it is an indication that the Rotamat has filled with rags and needs to
be activated to remove the rags. The ultrasonic level indicator does this. During the year the
Rotamat began acting erratically if at all. The level indicator was replaced to restore normal
operation. In order to complete this signal indication a new contact was also installed in the
electrical control cabinet. In 2014 monies were budgeted to do some significant upgrades and
repairs to the Rotamat.
The Rotamat operates in a harsh environment under difficult circumstances. About every ten years
or so these upgrades and repairs become necessary. It had been twelve years since the first overhaul
had been done. A date for pickup was scheduled and the manufacturer,Lakeside, sent a flatbed 18
wheel truck to transport the equipment to Illinois where the repairs would occur. A permanent
gantry was installed years earlier for lifting the 4800 pound piece of equipment to do onsite repairs
and cleaning and for removal to do offsite repairs. During the removal process the gantry failed and
the Rotamat fell into the roadway. A backhoe was used to complete the truck loading. After factory
inspection additional damage was discovered. The cost for the original upgrades and repairs plus the
additional damage equaled or exceeded the cost of a new unit. A decision was made to scrap the
unit and purchase a new one. A budget amendment was completed to add funding to the monies
previously budgeted. A new Rotamat has been ordered.Delivery is expected sometime in the spring
of 2015.
Grit Collector. The grit collector removes grit from the influent flow. Grit is removed at this
location to prevent excessive wear on downstream equipment. There are two grit collectors. One is
-4-

the primary collector and the other is a back-up. The primary unit, installed in the mid 90's,uses a
vortex motion to settle grit out of incoming wastewater. A pump removes the settled grit from a
hopper to a screw conveyor for removal to a dumpster. The pump is driven by a motor through the
use of a four belt pulley system. The belts wore out and broke and had to be replaced to restore
function. Later the pump quit pumping again. After inspection it was determined to be a worn out
seal and associated parts. This will not allow the pump to maintain prime and pump. A seal kit with
associated parts was installed to restore function. Later the screw auger stopped turning. It was
discovered that the drive shaft for the auger had broken. To get to the shaft bearing, housing and
bearing have to be removed. These items were significantly worn as well. A new drive shaft was
fabricated. This piece along with a new bearing and bearing housing were installed to restore grit
removal to the dumpster. The back-up collector,original equipment installed in the early 60's,uses
gravity to settle grit to a sump pump which pumps to a screw conveyor for removal to a dumpster.
Although this equipment is much older and less efficient than the newer vortex technology, the
gravity system is maintained for use during times when the vortex unit may be down for repairs.
During the course of the year the gravity grit removal system sump pump wore out and quit
pumping. A spare was available and was installed. The pump has been rebuilt and now a spare is
available in the event of the online pump failure. During the course of the year the screw auger
broke into. It was removed, welded back together, and reinstalled. The unit is now capable of
removing grit again when needed.
Influent Pump Station. The influent pump station transfers all incoming flow into the plant. The
station is equipped with four pumps. Their pumping capacities are 2,4,7,and 7 million gallons per
day(MGD). The 2 and 4 MGD pumps are the"work horses"of this pump station. They handle the
majority of the work on normal flow days. This spares wear and tear on the larger 7 MGD pumps
which are needed in cases of higher flows. They alternate based on run time hours until flows
increase to a level where both are needed together. The three larger influent pumps are equipped
with variable frequency drives. This allows the pumps motors to speed up and down as flows
increase and decrease. This is a more efficient way for the pump motors to operate and provides a
smoother flow through the plant. This is contrast to a start wide open, stop immediately off
operation.
All four pumps work together depending on flow. They are regulated by a pressure transducer
which senses the well level that the pumps pump down as it fills and empties. The pressure
transducer started failing causing the pumps to act erratically. A new one was installed to return
normal operation. All four pumps originally had packing "rope" around the shaft to prevent
wastewater from entering the shaft and causing accelerated wear. Packing requires a great deal of
attention keeping it tight and replacing as it wears out. To eliminate this work demand pumps can
retrofitted with a mechanical seal. Once installed it needs no further attention and lasts
approximately five years before replacement is necessary. In 2014 the last of the four influent
pumps was retrofitted with a mechanical seal.
Primary Clarifier. Primary clarification is the first treatment process for the removal of incoming
wastewater organic solids. There are two. They are circular concrete tanks seventy feet in diameter
and twelve feet of depth which increases toward the center of the tanks. At the very center of the
conical bottom is a hopper. Wastewater enters in through the bottom of a center column travels
upward and outward where it meets a baffle wall approximately three feet outward at the top of the
column. The wastewater flows outward from the center column. This baffle wall slows down the
flow of incoming wastewater allowing the organics to settle out. They also have a surface sweeping
mechanism which removes floatables,grease,into a single 1500 gallon collection box. There is also
a bottom sweeping mechanism which rakes the settled organic solids into the hopper. Both the
sweeping and raking mechanism are driven by a single motor/gear box mechanism. The grease
collection box has a mixer in it to keep the grease from solidifying and a submersible vertical
chopping pump for removal to a stabilizing treatment process. The grease is removed on an as
needed basis, usually every third day. The settled organics which by nature are abrasive are
removed from the primaries by a remote pumping building attached with piping to the hopper of the
primaries. Horizontal chopper pumps are used for the removal of the settled solids. There are two,
one for each primary. The settled organic solids are removed at regular intervals daily. The solids
are also sent to a stabilizing treatment process. During the course of the year several repairs and
upgrades occurred at this process.
-5 -

One of the motors failed and had to be replaced. A spare was used until a new one could be
procured. One of the drive gear boxes failed. Fortunately at the time, flows were low so only one
was online. Flow was switched to the other primary clarifier until a new gear box could be ordered,
received and installed. The primaries are equipped with a load torque system. It is there to protect
the drive system at times when heavy loads my build up. The torque system will shut down the
primary before damage is done to the gearbox. In conjunction with the torque system the primaries
have shear pins which also protects the drive system. The torque system is an electrical shut down
system while the shear pin is a mechanical. In the event of excessive torque, the shear pin can
"shear" before the torque system shuts down the primary. At two different times of the year the
shear pin sheared shutting the primary down. In the remote pumping building equipped with the
settled solids removal pumps,both at different times of the year had to be rebuilt. Also money was
budgeted for a spare. Sometimes when solids are in excess it may take two pumps to pump one
primary. Having a spare assures two pumps available at all times in the event one fails and has to be
sent off for repair. It can take over a month to have a pump rebuilt making a spare necessary. The
remote pumping building is notorious for gas buildup. In an attempt to minimize this, a new more
powerful exhaust fan was installed. Also, the main line that off gases, was relocated out of the
building into grease collection box of one of the primaries. The grease collection boxes are narrow.
The valve that stops flow from entering the boxes from backflows is located in the collection boxes.
In addition to being narrow dangerous gases can build up inside. From time to time the valves will
get clogged with grease and have to be cleaned. Entry into the box is awkward and dangerous if not
properly done. Money was budgeted to have the valves relocated making access easier and safer.
An in-ground vault was installed and the valve was moved here. During the relocation the piping
was noticed to be severely clogged. Time was taken to replace some of the piping and clean some of
the other.
Because of this, clean out ports were added to the vault making cleaning of the piping possible
without having to dig the piping up. While relocating the valve it was also discovered that the flange
around the piping exiting the grease collection box was broken. Time was taken to replace the
flange during the valve/vault relocation project. Plans are to do the second valve/vault relocation
project next fiscal year. While digging for the vault installation some of the control wiring to the
remote pumping building were dug up and cut. The wires are awkwardly located and have been dug
up and cut during other projects. The wiring was repaired. However, this time the wires were
relocated and grouped together minimizing this damage from reoccurring in the future.
Rotary Distribution (Trickling Filter). Biological wastewater treatment begins at this phase of the
wastewater treatment process. There are two rotary distributors each 130' in diameter. Wastewater
from the primary clarifier enters the center column of the circular rotary distributor. The center
column splits the water equally to four distribution arms. The arms have holes(orifices) in the top
which the water passes through then down the front of the arm. This causes the distributor to rotate.
Underneath the arms is a 5 foot deep bed of rock. Microorganisms grow on the rock surface and as
the wastewater trickles through (trickling filter)the bed of rock, the microorganisms start cleaning
up the wastewater. The existing rotary distributors (2) were purchased and installed in the mid
2000's. Unlike the previous two installations,the first two in the mid 60's and the second two in the
mid 80's, the current distributors are bottom load bearing style rather than top bearing style. This
style of distributor has not performed as well as the previous installations. There has been a
significant inability for the distributor to rotate. The decision was made and funds budgeted to
convert these distributors to top load bearing style. In an attempt to minimize the cost of these
conversions the District decided to purchase all materials and contract out all work for the
conversion project rather than return the units to the original manufacturer for a turnkey project. The
first step was to procure the conversion drawings and materials list from the original manufacturer.
Next bids were accepted for the fabrication, disassembly and reassembly of the units. Meanwhile
the District was in the process of purchasing the hardware, seals, and bearings for the distributor
conversion. Unit number one was started with. The conversion work was completed and the unit
was placed back on line. Work on unit number two has now been completed and too is back on line.
Other than this major retrofit job only one minor failure occurred. On unit number two one of the
turnbuckles or one of the support guide rods for the distributions arms broke and had to be replaced.
-6-

Filter Effluent Pump Station. The filter Effluent Pump Station (FEPS) collects all incoming flow
that has traveled through the primary clarifiers and trickling filters. It then transfers this water on to
the secondary system for further treatment. This station is equipped with four pumps. Their
pumping capacities are 2.1, 7.9, 7.9, and 9.2 million gallons per day (MGD). Here as with the
influent pump station,the smaller pump is the"workhorse". At this station the two 7.9 MGD pumps
alternate after equal run times to aid the 2.1 MGD pump during normal flows. The 9.2 MGD pump
is the high flow pump at this station. The three larger filter pumps are equipped with variable
frequency drives. This allows the pumps motors to speed up and down as flows increase and
decrease. This is a more efficient way for the pump motor to operate and provides a smoother flow
through the plant. This is in contrast to a start wide open, stop immediately off operation. In 2014
no major repairs,replacements,or upgrades occurred at this station.
Secondary System. The secondary system is the final biological treatment system consisting of three
square 500,000 gallons each aeration basins and two rectangular 1,000,000 gallons each secondary
clarifiers. The basins which are aerated are the "working" area of the system. Solids with
microorganisms are mixed and aerated providing an environment for wastewater stabilization. The
clarifiers are the "resting" and compaction area of the system. Solids settle to the bottom of the
clarifier until they are returned back to the aeration basins. As excess solids build up they are side
streamed to a solids stabilization process. The secondary system is operated by the use of various
valves and piping, control panels, traveling siphon bridges with valves and skimmer arms,
gearboxes, motors, pumps, and blowers. The system is also equipped with polymer feed system.
The blowers, two 75 horsepower (#1&#3) and two 100 horsepower are used to supply air to the
aeration basins. The number of blowers is based on dissolved oxygen demand. The demand is
monitored with dissolved oxygen meters. The blower system is electronically controlled. Because
of this the blower system has to be maintained constantly. To help with this a battery backup is used
in the event of a power interruption. This year the backup system failed and had to be replaced.
The traveling siphon bridge travels the entire length, 200', back and forth nonstop at adjustable
speeds. This is the piece of equipment that picks up and returns the settled "resting"
solids/microorganisms to the aeration basin or to the side-stream stabilization process. It is pulled
and pushed along with a 400' cable and has side stabilizer cables to help the unit run true. The
forward/backward movement cable is attached to pulleys. The pulleys are driven with a gearbox by
a motor to propel the bridge. A clutch mechanism is attached to the gearbox. It is a safety part. In
the event the bridge should get in a bind,the clutch will kick out the drive unit preventing extensive
damage.
One set of electrical sensor eyes are used to reverse the movement at each end of the clarifier.
Another set of eyes are also used for an alarm if the bridge "over travels". An electrical control
panel equipped with a variable frequency drive computer is the brain of the operation. Over the
course of the year several items were repaired or replaced. One of the 400' cables became frayed
badly and was replaced before it broke. The side stabilizer cables had to be adjusted on the same
unit. The same unit had a clutch problem early in the year. It kept slipping off the drive shaft
shutting the unit down. Later in the year the drive unit had to be completely rebuilt. A new gearbox,
motor,pulleys,shafts,and bearings were installed. On the opposite unit the variable frequency drive
failed and had to be replaced to restore equipment operation. The sensor eyes over time fade out.
When this happens they cannot see the equipment and tell it to reverse direction. An over-travel can
occur or the equipment may simply not reverse direction. The eyes faded out this year and had to be
replaced.
At times for various reasons solids will try to was out of the secondary clarifiers. If washout
becomes bad enough permit limitations could be violated. At these times polymer, a solids settling
chemical can be fed. It can also be used at times when incoming plant are low. Feeding polymer
will lower the outgoing solids therefore increasing the percent removal percentage between
incoming and outgoing solids. The permit requirement is 85% removal. The polymer feed pump
lost efficiency due to normal wear and would not feed adequate amounts of polymer. The two main
parts of the pump, the stator or housing and the rotor or feed shaft were replaced restoring pump
efficiency.
-7-

Disinfection. The final phase of the water treatment process is disinfection (pathogen kill) and
disinfection removal. Sodium Hypochlorite (bleach) is added to the wastewater flow in sufficient
amount to destroy potentially dangerous virus and bacteria. After this process, Sodium Bisulfite is
added to remove any remaining hypochlorite. This is necessary because hypochlorite is hazardous
to the aquatic life of the receiving stream.
The disinfection process area also incorporates the effluent caustic feed room and the effluent water
reuse station. Caustic is fed as necessary at the end of the disinfection process where pH's can be
depressed. The pH must be above 6 to meet permit limits. Caustic is very corrosive and difficult to
work with. It is bad for leaking at pipe joints and valves. Leaks can be dangerous,hard to clean up
and can etch concrete. There was one line leak that had to be repaired this year. During the year a
protective coating was applied to the floor and part of the wall to protect them from caustic leaks.
The reuse station uses water from the end of the disinfection process to help control floatable
material on the secondary clarifiers. There are two pumps at this station with one used at a time and
alternated on a monthly basis. One pump and motor from the same piece of equipment was repaired
at different times of the year. The hypochlorite building has two feed tanks. Only one is used at the
time and they are alternated per each load of hypochlorite received. The tanks are equipped with a
sight-glass for determining levels and when to reorder. One of the sight-glasses developed a leak.
The contents were transferred to the empty tank and the sight-glass was repaired before a large leak
could occur. The wastewater plant is in the process of changing out fluorescent,sodium vapor metal
halide lights to the more efficient LED lights. Although this is one of the newer buildings on site,it
was chosen in part as one of the first buildings to start the change to LED lighting because of the
difficulty of reaching the existing metal halide lights safely. The LED's were relocated to a safer
area. This is possible because of the illumination of the LED's.
Digesters and Stabilization. Digesters receive solids removed from the primary clarifiers. With heat
and mixing and occasional chemical addition (sodium hydroxide) for pH control, solids are
stabilized. There are two working digestion tanks and one resting where solids compact before
removal to storage and subsequent land application. Each working digester is heated with its own
heat exchanger. Each heat exchanger is a two chamber piece of equipment. One side is a heat
compartment and the other is a water bath. Solids recirculated between the two chambers where the
heat is transferred or exchanged.
Temperature settings for the heat compartment and water bath are controlled with a single dual
setting LED controller. The LED controller of one of the heat exchangers faded out. Without being
able to read the numbers, adjustments to the heat exchanger cannot be made. A new controller was
installed restoring use of the temperature adjustments. The LED controller receives its temperature
reading from a measuring device called a thermocouple. They are located in dry wells to keep them
out of contact with heat exchanger contents keeping them cleaner and more accurate. The LED
readings started becoming erratic. The dry well and thermocouples were upgraded to restore
accuracy. One of the heat exchangers became undependable. An inspection revealed several
electrical/electronic issues. Some controlling wiring had to be replaced
reconfiguration. And one of the control meters required some re-synchronization. After all of this
repair the heat exchanger began operating correctly.
Water is recirculated through the water bath as it is heated to the warmest water next to the heat
compartment. The recirculation is accomplished with the use of a small pump. One is located on
each heat exchanger. One of the pumps had a bearing and impeller wear out. These two items were
replaced so recirculation could resume. The recirculated water recirculates top to bottom through a
water jacket (container) attached to the heat exchanger. The seal between the jacket and heat
exchanger failed and began leaking water. The recirculation process is close looped. If too much
water leaks out the heat exchange shuts down. To prevent this,the seal was replaced.
A byproduct of the stabilization process is methane. It is captured and stored so it may be used for
fuel to heat the exchanger. The heat exchangers are also equipped to nm off natural gas as well at
times when methane production may be low or outside temperatures are colder requiring the use of
supplemental fuel. For this operation, gas valves are required for both types of fuel. Methane
availability can be increased by the use of a pearth unit located on the top of the working digesters.
-8-

Methane is directed to the pearth through pipe work. It is then compressed and forced back down
into the digesting solids. This action liberates methane that is entrained in the digesting solids.
The net effect is the release of additional methane for heat exchanger heating. One of the two
compressors failed and had to be replaced to resume this process. Another byproduct of the
stabilization process is water. It collects in the digesters and the gas capture system. The water in
the digester must be removed to maintain"working"space in the digester. The removal is done with
a selector or slotted drain pipe located in the water collection area of the digester. The control of
water removed is with a valve and sight-glass located in the adjoining digester building. Each
digester (3) has this set up. The decanted water is returned to the wastewater plant. One of the
valves seized up and had to be replaced to continue water removal. Water is removed from the
methane gas so it will burn more efficiently and hotter. The removal is accomplished with the use of
a drip trap. They are strategically located throughout low spots in the gas piping system. Gravity
causes the water to flow into the traps. Specially designed,the traps can be opened to drain off the
water without releasing gas. This water too is returned to the wastewater plant. Several traps seized
up and had to be replaced to continue water removal. As solids become stabilized they are
transferred within and ultimately out of the digester process. All of these transfers are done with a
progressive cavity pump. This style of pump transfers with a smoother steady action to accomplish
the most efficient transfer. This pump quit working. The pump was disassembled to find the reason
why. It was discovered that the rear end gears had worn out. This was a result of normal wear and
tear over a significant amount of time. The gears were replaced and pump began operating
efficiently. Each digester is a circular concrete tank with a metal top. It is 45' in diameter,made
with 'A inch steel and weighs 80,000 pounds. The metal top is designed to float on the solids
contained in the concrete tank. It needs to be able to float as the solids in the digester are added to
and taken out of. To be able to float it is constructed with a roof,side and a bottom. One of the tops,
fifty years old has had a roof well taken care of. It has been coated with a protective coating
numerous times. However,the sides and bottom had never been coated since its original installation.
They are not accessible with the top inside the concrete tank. Over fifty years holes developed in the
side and bottom. A contractor was hired to remove the top and place it on cribbage on the ground at
a level where the side and bottom could be reached. All of the old metal on the side and bottom was
replaced. The welding process to get this amount of metal took around five weeks. While this repair
was ongoing,wastewater staff cleaned out the inside. This is done every seven to ten years and was
due to be done. It is done to remove undesirable debris that builds up over time. Around 250,000
gallons of solids with undesirables was removed. After removal of the contents an inspection of the
inside was conducted. The inside contains a series of pipe work for the movement of solids in and
out and also for recirculation. One pipe was broken completely into and another had developed
holes in it. These pipes were replaced. Also the selector that removes the water from the digester
was reworked. The one that was in had slots in it that were too narrow. It was replaced with one
with larger slots. After the completion of all work was done including coating the newly added
metal side and bottom with a specially designed coating for this application, the metal top was
reinstalled into the concrete tank.
Biosolids Thickening. Excess solids from the secondary treatment process are thickened by gravity
settling tanks and a drum concentrator with the use of polymers. Polymers when mixed with solids
create a reaction which causes solids to concentrate (floc) and water separate. The purpose is to
minimize the solids removed from the treatment plant because removal charges are based on the
amount of gallons removed. Excessive solids from the secondary system enter a pump station by
gravity flow. From here the solids are pumped to a gravity settling tank to begin the thickening
process. There are two gravity settling tanks and one drum concentrator. Current flows necessitate
the use of only one gravity settling tank. This provides back up for the tank on line. The gravity
settling tank and drum concentrator can be used separately or in series. Wastewater operations
dictate which is used but normally the series option is used with the solids first entering the gravity
tank. The gravity settling tanks are switched regularly to ensure proper operation and even wear and
tear on equipment. The pump station is used to send solids to the gravity settling tank.
The gravity settling tanks are equipped with a motor and gearbox which are attached with a shaft to a
mixing paddle located inside the gravity tank. The gearbox was removed and sent off for repair.
Once returned it was reinstalled. The gravity tank has been returned to service. Concentrated solids
again gravity flow into the drum concentrator for additional thickening. Once thickened the solids
-9-

are transferred with a conveyor belt and deposited in a stainless steel collection hopper. The hopper
has an aluminum top for controlling splash from the fall of solids off the drum concentrator
conveyor belt. The top has been removed numerous times over the years to perform maintenance on
some internal equipment and for routine clean up and wash down. The topo has been bent and
warped. A new top was built. This time a more robust top was made making it heavier and more
difficult to move. To aid opening this new top for the above mentioned attention,it was hinged with
gas filled lift shocks. Solids are removed from the hopper with a progressive cavity pump. The
pump became inefficient. It was taken off line an inspected. The working parts of the progressive
cavity pump are the stator and rotor. The stator is a stationary rubber casing. The rotor is a metal
worm like shaft. As the shaft rotates within the stator it creates steady state suction. Over time these
parts wear out an efficiency of the pump is lost. The rotor and stator were replaced restoring the
efficiency. The polymer used for the concentration of the solids and the water to separate is received
in a concentrated solution. It must be mixed on a regular schedule to keep the contents from
separating and becoming ineffective. A pump is used to keep the polymer mixed. Over the course
of the year,a motor and gearbox had to be replaced to keep the mixing ongoing.
A major modification and upgrades occurred at this building in 2014. The drum concentrator,nearly
thirty years old, was taken out and replaced with a gravity belt thickener(GBT). It is a much more
efficient thickener,and more user friendly. By nature these machines give off mists. To make using
the new GBT better a wall was installed isolating the machine from the user. It was also vented to
the outside with an industrial sized stainless steel vent hood. The control panel was moved outside
the GBT room. The user can view the operation of the GBT through an observation window.
Another change was made to make the GBT easier to use. With the drum concentrator, flow was
introduced to it by gravity with the use of a valve. This method was awkward and difficult to
control. With the GBT, a progressive cavity pump was installed ahead of the GBT
controlling flow into it. It provides a steady constant flow into the GBT and needs no adjustment.
The building itself was doubled in size. The original building had become cramped with equipment
additions. And with the GBT isolation, wall space became very tight. Also, the undiluted "bulk"
polymer tank was located in a shed next to the thickening building. The shed has no spill protection
containment. By expanding the building a containment area was added for this chemical. In
addition,the diluted"day"polymer tank was relocated to this extended area as well. It too has spill
containment.
An upgrade was done with the two polymer tanks as well. Previously the tanks were horizontal.
This type of tank would not allow for complete removal of the polymer and over time a residue
would build up. It was difficult and time consuming to remove. To remedy this situation the
horizontal tanks were replaced with vertical,conical tanks which allow all polymer to be removed.
Three contractors were used. One to install the GBT and some ancillary equipment. One to build
the steel addition with isolation wall and most of the major electrical. One contractor was used to
paint. Wastewater staff also played a significant part in readying the building for use. Everything
from grated walkways with handrails,smaller pump relocation, chemical feed pipe relocation,water
line relocation, various pump stands, setting the two polymer tanks in place, and some of the
electrical relocation.
Lime Stabilization. Waste activated thickened solids are stabilized through the use of lime. Time
and pH's dictate the stabilization requirement. Lime is received in dry form and is transferred to a
storage/feed silo with a special lime delivery truck. The truck pressurizes and blows the lime into
the silo. As it enters the silo the lime passes through filter bag dust house. The purpose is control
the dusty lime. The dust house had become worn out over thirty years so a new one was purchased
and installed.The control panel for dust house was also thirty years ole. It was in need of repair and
upgrading as well. The original cabinet was regular metal and although regularly painted over the
years, the environment was harsh. A stainless steel cabinet already located on site was used. This
metal will withstand the environment much better. The inside of the cabinet was rebuilt and
upgraded for control of the dust house. Unlike the original dust technology, improvements have
made the new dust houses more efficient. Now the new dust house is equipped with an air
- 10-

compressor. It is located in a remote shed and piped to the dust house which is located on the top of
the thirty foot tall lime silo.
During the lime truck to silo transfer the compressor automatically blows every few moments
through the bag keeping lime buildup to a minimum increasing effectiveness of the bag capture.
During use, the lime falls down by gravity toward a preparation tank. To help this gravity fall a
series of vibrators are located from the top of the silo to the bottom. Two of the vibrators had to be
replaced to maintain lime gravity falling through the lime silo. At the bottom of the lime silo,which
is conical,there is a feeding mechanism. The mechanism became erratic. It is adjustable depending
on the needs of the equipment. To remedy this, a human machine interface(HMI) operator control
panel had to be replaced. The mechanism rotates to accomplish the feed. Because of one of the
vibrators is located near the feed mechanism it kept coming loose. To stop this it was welded in
place. Also while doing some research it was discovered in the event of the feed mechanism failure
it may take several months to acquire a new one.
This process cannot afford this lengthy down time. The decision was made to purchase a spare for
inventory. A new one has been stocked. The dry lime is fed through the feeder into a preparation
tank where water is added creating a slurry. Lime slurry tanks are made in 300 gallon batches.
Once well mixed in the preparation tank the slurry is then gravity flowed into one of two 12,500
gallon mixing tanks containing solids to be treated. The two mixing tanks are used alternately. It
may take anywhere from four to eight 300 gallon lime slurry batches to properly stabilize 12,500
gallons of solids. The 12,500 gallon mixing tanks are equipped with mixers to achieve proper
blending of the solids with the lime and to keep the lime in suspension. At different times of the
year both mixers failed and had to be sent off for repairs. Once lime slurry is added to the solids in
the mixing tank and proper pH level is reached,the treated tank is ready for transfer to a downstream
process. A gate valve located on each mixing tank is opened and the treated solids gravity flow into
a pumping station for this transfer. These two twelve inch gate valves are opened often. To make
the opening of these two valves more operator friendly,electric operators were installed.
The downstream process consists of three additional holding tanks also equipped with mixers. Here
additional pH monitoring is done for a specified amount of time. Two of the holding tank mixers
failed. Due to the age of these mixers,parts are difficult to fine. The decision was made to replace
these two mixers with new ones. With all these mixer failures,luckily spare mixers were on hand to
keep all processes up and running.
Million Gallon Stabilization Solids Storage Tank(MGT). The MGT stores all stabilized solids from
the digester stabilization process and the lime stabilization process. The solids remain in storage
until they are removed by an outside contractor for land application to farm land. The solids contain
nutrients that are used for fertilization. The solids also contain water that is beneficial to the farm
land. And the solids also help remediate soil. The MGT contains five mixers that are used to keep
the two different stabilized solids blended,to help keep lime in suspension with the stabilized solids,
and for odor control.
In 2014 no mixers had to be removed for repair. The level in this tank is measure with a level
transducer. The transducer quit working and had to be replaced so the contents of this twenty foot
tall tank would be known. One the MGT is full the outside contractor comes in to remove the
stabilized solids. This is accomplished with a stationary pump,piping, and valving. The valve the
contractor uses to fill the tanker truck became very difficult to open and close, slowing down the
removal process. The valve was replaced so it now can be opened and closed easily. Over the years
on occasion there have been discrepancies over the gallons actually hauled. To remove any doubt, a
flow meter was installed on the fill line going to the tanker truck.
During the storage water will still separate from the solids. Also the tank size, one million gallons,
is like a large rain gauge. This excess water is removed with a decent system saving thousands of
dollars each year. The savings comes from the number of gallons removed. The outside contractor
charges by the gallon. All the decanted water is returned to the plant.
Even though the MGT is mixed constantly, lime still precipitates out. Over time it builds up on the
tank bottom. This reduces the effectiveness of the mixers. Approximately once a year,the tank is
- 11 -

emptied and cleaned to remove the built up lime.This time also allows for the mixers to be inspected
for wear and tear and an opportunity for the oil levels to be checked. Also,the integrity of the MGT
can be inspected.
Generator. The plant generator is used to supply the entire plant with power in the event utility
power is interrupted. The generator is on a quarterly preventative maintenance program with a
contractor to maintain the engine.However, if the transfer switch which transfers power from utility
to generator does not function properly the generator cannot be used. The transfer switch is now
also on a regular scheduled maintenance program with an outside contractor.
In 2014 the generator, now seventeen years old, underwent numerous repairs. In January a fuel
manifold had to be installed to provide proper fueling of the engine. In June while running on a
scheduled curtailment for the power company,the generator began losing power.However,its gauge
would not let the transfer switch return to normal power. Finally the main breaker was disconnected
on the generator so that the breaker to normal power could be turned back on. Of course this action
voided the curtailment run. The only waiver we get for the summer season had to be used to avoid a
fine. Fortunately,the generator repairs were made before the next request for curtailment was made.
Some of the repairs made included a sensor that tells the engine what RPM to run,part of the main
controller panel, the transfer switch controller, repairs to the transfer switch breaker, a fuel throttle
controller was replaced, a fuel pump and various other gaskets, seals, hoses, filters as well as a
starter,new batteries as well as many other supporting parts.
SCADA (Supervisor Control and Data Acquisition). SCADA is a computer-based program. It
brings site information into the central operations center. SCADA is a useful tool by providing
monitoring information to be used for more efficient plant operation. It also brings remote site
alarms into the operations center, which provides better control over plant problems. The SCADA
system was expanded to additional areas in 2014.
The primary sludge pumps that remove the settled solids in the primary clarifier and send them to
the digesters were added to the system..Now the on/off status can be monitored. Also they were set
up on a trend chart so the run times can be verified. In the digester building decanting waster as it is
released from the stabilization process is critical for maintaining working space in the digester.
Often to get the decanting to start water is back-flushed into the digester to start the process. It only
takes a few minutes to accomplish this. If forgotten, in no time the back-flush water can force the
solids in the digester out of the top creating difficult spill to clean up. To remedy this, flow sensors
were added to the back-flush water lines. They are on a preset timer and if this time is exceeded,an
alarm will go off.
Finally an additional SCADA monitoring station was added to the system. Adding this extra
monitoring station increases the chances that if a problem occurs on the plant site it will be
discovered in a timelier manner. Due to the size and complexity, and some parts of the SCADA
system beginning to age, several repairs were necessary throughout the year. Also, to keep the
SCADA computer working reliably and efficiently, the data from 2014 was unloaded on to an
external hard drive.
12"pump installation. The 12 inch pump installed at the head-works of the plant in 2000 remains a
valuable tool in preventing spills. In the event of high flows or maintenance repairs, water can be
removed to two abandoned secondary clarifiers. These clarifiers were taken off-line in the early
eighties after plant upgrades. They were originally used for stabilized biosolids storage. The
capacity was increased by extending a wall up from where the weir overflows were when used as
secondary clarifiers. This increased the storage capacity of the two tanks to 750,000 gallons. After a
dedicated biosolids tank was constructed, the two abandoned tanks were dedicated to spill
containment. Once stored, wastewater can be returned to the plant with an existing pump station.
Some pipe work has been added to this station and depending on conditions,water could be returned
as the tanks are filled. This further increases holding capacity or downtime, during high flows or
maintenance and repairs. In 2014, 10,912,428 gallons of wastewater were stored. Since setup in
2000, 66,113,586 gallons of wastewater have been prevented from spilling. At the average flow of
4.0 MGD in 2014,this would be 16.5 days of flow.
- 12-

Another means of spill control is with a backup generator. The wastewater plant must continue to
run in the event of power interruptions from the power-supply company. Power interruption can
occur from equipment failure, road accidents, and weather events, such as ice storms, electrical
storms, tornadoes, and hurricanes. A 750 kilo-watt generator is on site for events and can supply
enough generated power to run the entire plant. In 2014, there were two power interruptions
resulting in the use of the back up generator for power supply. The first occurred on January 11th
and was due to storm conditions. The generator was used for 10 minutes and prevented 50,694
gallons from spilling. The second occurred on July 9th and was also due to storm conditions. The
generator was used for 5 minutes and prevented 9,375 gallons from spilling. In total 60,069 gallons
were prevented from spilling by use of the backup generator for the two events covering 15 minutes.
The emergency generator is also used to curtail. The District is under contract with Dominion
Power. From May 16th through September 30th (summer curtailment) and from December 1"
through March 31st(winter curtailment), Dominion can request the wastewater plant to supply its
own power for parts of the day during peak demand. These requests usually come on the hottest
days of summer and the coldest days of winter. Dominion can then send power that the District
would normally use to other places of need. Winter requests are usually from 6am to 11 am(5 hours)
but can be 5pm to 10pm(5 hours)also possibly on the same day. However,each requests counts as
one run. Summer requests are from 2pm to 9pm(7 hours). The contract is limited. In the winter
requests to curtail are limited to 13 or 65 hours and summer 19 or 133 hours. In 2014 the
wastewater plant was called to run 13 times during the summer curtailment. There were 10 winter
calls. The District does incur the cost of diesel fuel. However, the rate structure the wastewater
plant has because of the contract off sets this cost and provides electrical energy savings. An added
benefit of this program is that it provides a means to exercise the generator. This keeps the generator
in better running condition and exposes any potential problem. It would be better to find out a
problem during a curtailment than an actual power outage. Dominion does provide one waiver per
curtailment season each year for such cases where a mechanical issue should arise. By having the
generator under a contracted quarterly preventive maintenance program hopefully mechanical
problems will be minimized or eliminated.
Biosolids land application program. This program permitted by the Environmental Protection
Agency(EPA)ran well in 2014. In the required annual report to North Carolina Division of Water
Resources(NCDWR)and the EPA,there were no deficiencies or spills.In 2014 there were 268 lime
stabilization events at 11,250 gallons per event for a total of 3,015,000 gallons. This is 73.4%of the
days in a year. The anaerobic digestion process produced an additional 254,375 gallons of stabilized
solids. Although these solids have met all requirements for stabilization,they are also limed. This is
done solely for the purpose of odor control. The wastewater plant has entered into agreement with
area farmers for the use of their land for biosolids application. The farmers in turn receive the
nutrient value, moisture content, soil remediation, and lime, which is a by-product of ph control in
the treatment process of the biosolids. If necessary, additional lime can be applied. There are 3100
acres,consisting of 128 fields,available in Halifax,Northampton,and Warren Counties. All acreage
was inspected, approved, and permitted by the State of North Carolina. Using EPA approved
treatment processes, 3,341,800 gallons of stabilized biosolids were safely applied to area lands,
consisting of 10 fields on four different farms covering 319 acres, for beneficial reuse. Cost of this
application process was approximately $96,000. Cost of treatment to stabilize solids is separate.
Land that grew fescue,soybeans,and cotton was applied to. The amount applied in 2014 is down 13
% from the previous year. Charges for application are based on gallons. In an attempt to save
application costs,biosolids are thickened as much as can possibly be handled. The removed water is
returned to the treatment plant. Also,once biosolids are placed in storage for land application,water
is further separated. This water along with environmental water (rain, snow, etc) is decanted and
returned to the treatment plant. In 2014, 215,291 gallons was decanted, at savings of$7,255.
Although 3100 acres of land is permitted and storage of 1,000,000 gallons is available, at times
application is difficult due to weather conditions,crop status,and crop rotation. Owning land would
provide an outlet for these times. In 2004,the District purchased a suitable land application site. It
is located in Northampton County where the District already has farmer owned land permitted. The
land has been developed for livestock(cow)operation. The area has been split into two fields. One
contains 41.8 acres of fescue and the other contains 67.2 acres of bermuda.
- 13-

Since purchasing the land, investment improvements continued in 2014. Improvements have been
going on for nearly nine years. In 2014, the District over seeded the Bermuda with annual rye.
Because Bermuda goes dormant in cold weather months the rye over seed makes the Bermuda
acreage available for nutrient uptake if application to this site becomes necessary. The District has
strived to develop a model site. In 2014, nearly$12,000 was spent to maintain and enhance the
application site. This included the rye overseeding of the Bermuda and some maintenance of the
exterior fencing. Limbs and vegetative undergrowth were encroaching on the fence. To avoid
damage and provide access to the exterior fence this vegetation was removed. In 2014,the District's
site was used for land application. It was divided into two sides with different vegetation on each
side. One side has fescue and the other Bermuda. In October an application to the fescue side
occurred. It received 601,400 gallons over a five day period. This was an average of 120,280
gallons per day.The gallons applied to the fescue did not exceed the maximum allowable application
as measured by its nutrient uptake. There was no application to the Bermuda in 2014.
In 2013 the land lease came up for renewal. The District developed a land use management plan and
then advertised for bids. Sealed bids were received and reviewed and afterwards awarded the lease
renewal to the current lessee. The contract is for a five year period.
Industrial pretreatment program. In 2014 the industrial pretreatment program had oversight of three
significant industrial users. One user has a categorical discharge pipe. Five non-significant
industrial users are permitted to send flow to the wastewater treatment plant. Significant and non-
significant status is determined in part by the volume of flow discharged and the pollutants in the
discharge. The pollutants,carried by certain industrial wastes,determine the categorical status of an
industry. Each industry, whether classified as significant or non-significant, is issued a permit with
limits and monitoring requirements. In 2014 there were no significant industrial users in significant
non-compliance; a status based on the number and types of violations of the permit. There were six
notices of violation sent for permit violations.
The pretreatment annual report(PAR)was submitted to the state pretreatment unit on February 14,
2014. A letter, dated August 8,2014, was received stating review of the PAR indicates the repot in
good order and satisfied the requirements the North Carolina Pretreatment, Emergency Response,
and Collection Systems Unit(PERCS).
All industrial permits expired in 2012. Permits were renewed with an effective date of May 1,2012
and an expiration date of May 31, 2017. Two industries had permit modifications in 2014.
However,the permit expiration dates did not change.
Monitoring Laboratory. The District wastewater plant has an on-site monitoring laboratory.
Analysis for NPDES reporting to the Division of Water Quality must be performed by a certified
laboratory. The laboratory is certified by the North Carolina Division of Water Quality Laboratory
Certification Section. In order to become certified the laboratory facility must meet space and
equipment specifications as well as analysis performance evaluation. The laboratory is currently
certified for twelve inorganic parameters and four Vector Attraction Reduction options for the
treatment of biosolids. The laboratory receives samples from approximately 39 sampling points that
include plant monitoring, industrial monitoring, performance evaluation studies, septage hauling,
and collection system samples.
The laboratory has two full-time and one part-time technician, a laboratory supervisor, and
laboratory manager. One laboratory position became vacant in 2013. The vacancy was filled in
2014.
The laboratory currently holds certification from NCDENR/DWR Laboratory Certification Unit. To
maintain certification, the laboratory must complete an annual performance evaluation study and
submit the results to the state certification unit. This performance evaluation must be in the form of
a"blind' study. Study samples are ordered from a state approved vendor. The study sample values
are unknown to the laboratory. The samples are analyzed and the results are submitted back to the
vendor for grading. If the laboratory fails to achieve an acceptable rating on a parameter for three
consecutive samples,the laboratory could lose certification for that parameter. If the certification is
- 14-

lost, the laboratory must go through a recertification process as if they had never achieved
certification.
The laboratory submitted all required evaluation studies and received an acceptable rating on all in-
house study parameters. The laboratory received e-mail notifications from the state laboratory
certification unit on March 10, 2014 that it had received notification from the proficiency testing
provider that it was in receipt of acceptable evaluation study results from the provider.
Additional requirements of the program include state inspections, quarterly in-house blind studies,
maintaining a quality control program and a chemical hygiene plan, a chemical inventory plan,
equipment calibration and certifications,and certification fee.
The laboratory also works in association with the pretreatment program and biosolids program in
that analysis of samples taken by pretreatment technicians and plant operators are brought to the
laboratory for analysis. A laboratory technician is also responsible for entry of the resulting data
into a spreadsheet that is used by the Pretreatment program for its Long Term Monitoring Plan.
Laboratory technicians are also responsible for data entry into the plant operations spreadsheet used
for NPDES permit compliance monitoring and plant process control.
The laboratory works in coordination with the state certification branch to certify field testing
equipment for the surrounding communities with small treatment facilities who work on limited
funds. At this time,the laboratory assists five small facilities with equipment certification.
Fats, Oils, and Grease (FOG) Ordinance. The Roanoke Rapids Sanitary District adopted its first
Fats, Oils and Grease(FOG)Ordinance in 2005. Since then operational issues under the ordinance
arose. In 2008,the District addressed those in a revision and subsequent adoption of new ordinance
language.
In 2014,there were 54 restaurants in the District database. There were no new restaurants to open in
2014. There were two restaurants to close during 2014 leaving a total of 52. Inspections of the
restaurants and updates to the database continued in 2014. One restaurant that had an outdated
indoor trap moved to a new location with a new outdoor grease trap.
There was no Notice of Violation.One Notice to Correct was sent out to a local school in 2014.
There were no SSO's or other major blockages that were attributed to FOG in 2014.
FOG public education is a requirement of the wastewater collections system permit WQCS00027.
Ongoing efforts from 2013 continued in 2014 with the airing of a FOG slide that airs on local
television Channel 15 and the addition of a FOG pamphlet enclosure in one billing cycle. There was
also an article about the wastewater treatment plant in the Daily Herald Newspaper that mentioned
the FOG program and its goals. FOG educational posters and mailbox inserts were distributed to
several high density housing complexes as well. The administrative staff continues to distribute a
FOG ordinance package to all new Food Preparation Facilities when opening a new account. The
administrative staff also gives out industrial waste surveys to each person who opened a commercial
account that asks questions regarding food preparation and grease traps.
National Pollutant Discharge Elimination System(NPDES)permit. The wastewater treatment plant
has an NPDES permit. It is issued by the North Carolina Division of Water Resources (NCDWR)
after final approval is granted by the Environmental Protection Agency (EPA). The permit
authorizes discharge of treated wastewater to the
Roanoke River. The current permit which became effective March 2013 is valid through March
2017.
The current permit comes with some significant changes. Due to a huge data base of testing
parameters from over the years and due to an exceptional performing facility, reduction in the
amount of testing was granted. Carbonaceous Oxygen Demand, Ammonia Nitrogen, and Fecal
Coliform were reduced from five days per week to two. Also Annual Priority Pollutant Scans were
reduced from one a year for four year to one a year for three years.
- 15-

A new addition to the current NPDES permit was the additional requirement of a Mercury
Minimization Plan(MMP). All waters of the state are recognized as mercury impaired. As a result,
a statewide fish consumption advisory for mercury has been established. As a response, DWR has
issued a statewide total maximum daily load (TMDL). The TMDL calls for a 67% reduction in
mercury levels. Most of the mercury, 98%, comes from atmospheric deposition. Only about 2%
comes from point sources such as wastewater treatment plants. Although the contribution of
mercury from wastewater treatment plants is small,they have also been incorporated into the overall
reduction of mercury in the waters of the state. Because the RRSD WWTP has a flow above 2 MGD
and has detectable mercury in its effluent, the MMP is required. Typically, MMP's focus on three
areas. First, an internal WWTP review of mercury containing products and their disposal.
Secondly, pretreatment controls on non-domestic users. And third, outreach to the general public
regarding the proper use and disposal of mercury containing household products. DWR provided a
model MMP which could be adopted or a completely independent plan could be developed. The
RRSD WWTP used the state's model with some of its own additions. The permit had a
development date requirement which was met. MMP's do not have to be submitted to DWR for
approval. The plan only has to be available for review by DWR plant inspectors. Two years after
the development deadline date implementation must begin. A summary of the plan's activities will
be submitted as part of the next NPDES permit renewal process.
A requirement of the wastewater plant through its NPDES permit is quarterly chronic toxicity
testing. The test involves using a predetermined amount of effluent along with a macroscopic
organism. The wastewater treatment plant contracts this test with a private independent laboratory.
They collect sample and run the test. Ceriodaphnia are placed in the effluent and must survive and
reproduce for a specific length of time. Results of the test are either pass or fail. A pass indicates
the absence of substances in the effluent which may be harmful or threaten aquatic life. The
wastewater plant has been required to test for chronic toxicity since April of 1993 or twenty-one and
one half years. To date only one test has received a fail result. This occurred in July 2001. This test
was collected and tested by North Carolina Division of Water Resources(DWR). DWR has run this
test again with all passing. The latest was conducted in March 2011.
Another testing requirement of the NPDES permit is the annual priority pollutant analysis (APPA).
As indicated, it is an annual test that checks the effluent for conventional and non-conventional
compounds, total recoverable metals, volatile organic compounds, acid-extractable compounds, and
base-neutral compounds. These substances, if found in sufficient quantity, could be harmful to the
wastewater plant, receiving stream, and the public. To date, no substances have been found in
significant quantity to cause harm. The test is done seasonally over the term of a five year NPDES
permit.
The wastewater plant has a general storm water permit. It was received through an application
process as required by the NCDWR. A requirement of this permit is a written storm water
management plan. The plan is used to evaluate potential pollution sources and to select and
implement appropriate methods to prevent or control the discharge of pollutants to stormwater
runoff. As a part of the plan, semiannual preventative maintenance evaluations and semiannual
inspections of site runoff areas are required. Another requirement of the plan is annual employee
training. The current permit expires on May 31'`2018.
NCDWR also requires an Annual Performance Report(APR). The report must contain at minimum,
general information, performance, deficiencies, violations, spills and bypasses, any known
environmental impacts,and corrective measures to address deficiencies or violations. Also,from the
APR a condensed Consumer Confidence Report(CCR)must be distributed to the customers of the
District with information on where to obtain the APR. This information is posted on the Roanoke
Rapids Sanitary District's web site.
The Division of Water Resources (DWR), Water Quality Regional Operations Section ( WQROS)
conducted one site inspections in 2014. The site inspection was a solids generation and land
application inspection. The inspection was a result of the Land Application of Residual Solids
permit the WWTP has been issued. It was renewed in 2007 and is effective until 2016. This
occurred on November 19t. Areas evaluated included review of required records,facility equipment
evaluation and operation and a site visit to one of the most recent areas residuals were applied to. In
- 16-

addition,sampling and storage were inspected along with other miscellaneous questions in regards to
the program. The compliance inspection report received stated that treatment and storage units were
well maintained and documented and that the Residuals Management Program was compliant.
A wastewater plant inspection did not occur in 2014. The last inspection was December 20,2013.
Plant operations were deemed to be compliant.
Safety program.The safety program within the District is very active and assertive in its approach to
the protection of the employee. The program consists of a safety officer that is Manager of
Environmental Safety and Health (MESH) Certified. The safety program is also comprised of a
safety committee, incident/accident committee and appeals committee. The safety officer also sets
up the monthly safety meetings, coordinates the activities of the safety committee, keeps up with
safety regulations, and many other various safety activities. The safety committee prepares safety
policy programs and updates current ones. They also do site inspections and produce potential
hazard punch lists. The safety committee and safety officer also keeps up with and prepares for
updating regulations and integrating new regulations of OSHA. The incident/accident committee
reviews all potential accidents and accidents. The appeal committee follows up the safety committee
recommendation at the request of an employee. The attempt is to minimize the seriousness of an
accident and ultimately prevent accidents. As a result of the awareness and training from the safety
program, there were no loss work days in 2014 at the wastewater treatment plant. This makes the
9th straight year the wastewater plant achieved this accomplishment. The Sanitary District was
previously involved with the North Carolina Department of Labor (NCDOL) OSHA SHARP
Program. NDOL works with and inspects companies by company's request. After DOL
requirements are met, companies are awarded SHARP recognition. Participating in this program
exempts companies from unannounced inspections with possible fines. The District remained in this
program for several years before NCDOL restructured the program and removed the District from
this program. The correct program now is the STAR Program.
The Roanoke Rapids Sanitary District was inducted into the STAR Program in late 2013. The
District qualified for the public sector STAR Program of which not many companies are a part of.
During OSHA's review, all policies and procedures were reviewed to ensure that District's program
was sustainable. This along with the aforementioned programs must be maintained. Also,an annual
report must be submitted, usually in February, for North Carolina Department of Labor(NCDOL)
for review to ensure compliance and sustainability. It includes accomplishments of the past year and
goals for the upcoming year along with other requirements. Another requirement is that the District
actively participate in the annual STAR conference. This is one of the big differences between the
SHARP Program and the STAR Program. Employee involvement is mandatory from top to bottom.
The conference,which is held for three days in September,includes safety presentations,roundtable
discussions and seminars.
In addition, a result of the STAR program initiated the need for an electrical energy survey. This
survey is to identify the electrical hazards of the treatment system and inform employees on the
safety aspects on working on and around energized equipment. This required the need for an outside
contractor. The contractor was hired to perform a short-circuit study,protective device coordination
study and arc flash hazard analysis. These analyses develop electrical safety program which
includes hazard identification and risk evaluation procedure. All equipment was analyzed for
potential risk. Then labels were attached identifying the danger of working on energized equipment
and the necessary information and required personal protective equipment for working on the
equipment safely. The District developed a written program as well. The employees then went
through an arc flash training program.
The District is committed to engaging employees in the STAR Program and continues to improve
the safety attitude of all employees while providing a safe and healthy atmosphere in which to work.
B. By month,list of the number and type of any violations of permit conditions,
- 17-

environmental regulations,or environmental laws,including(but not limited to):
Permit limit violation
1. C.S.: One
2. WWTP: Four
January:
TSS weekly violation(1-4)=78.9 mg/1(Permit limit=45 mg/1)
TSS weekly violation(1-18)= 106.3 mg/1(Permit limit=45 mg/I)
TSS monthly violation =47.1 mg/1(Permit limit=30 mg/1)
February:
TSS weekly violation(2-1)=46.2 mg/1(Permit limit=45 mg/1)
Monitoring and Reporting Violations
1. C.S.: None
2. WWTP: None
2014 Sanitary Sewers Overflows(SSO)
1. C.S.: There were 22 reportable SSO in 2014.
1.03-27-14 Manhole C92 and C93 in Gaston est. 500 gal.
2.04-09-14 Manhole 136 est. 1200 gal.
3.04-15-14 Basin B Manhole 46 est. 1725 gal.
4.04-15-14 Manhole 46 River Rd.est.2500 gal.
5.04-15-14 Basin B Manhole 24 est.700 gal.
6.04-15-14 Basin A Manhole 54 est. 18000 gal.
7.04-30-14 Basin B Manhole 46 est.320 gal.
8.04-30-14 Basin A Manhole 54 est.9350 gal.
9.04-30-14 Basin G Manhole 46 est. 10350 gal.
10.06-03-14 Carolina and Wyche St.est.2250 gal.
11.07-24-14 Manhole 54 at Belmont est. 1125 gal.
12.07-21-14 Manhole 46 Starke St.est.400 gal.
13.07-21-14 Manhole 13B est.750 gal.
14.09-09-14 Manhole 182 at Kapstone est. 1200 gal.
15.09-09-14 Manhole 11B est.5400 gal.
16.09-09-14 Manhole 106B est.3000 gal.
17.09-09-14 Manhole 54 at Belmont est. 12600 gal.
18.09-09-14 Manhole 46 at 3th and Starke 1000 gal.
19.09-09-14 Manhole 42 at 13th and Marshall est.4275 gal.
20.09-09-14 Manhole 13B est.7200 gal.
21.09-09-14 Manhole 46 on River Road set 19700 gal.
22.07-21-14 Manhole 54 at Belmont est.2700 gal.
2. WWTP: N/A
Bypass of Treatment Facility
1. C.S.: N/A
2. WWTP: Seven(There were two on three different days for six of the bypasses).
April 15th(two events): Over four inches of rain fell in five hours increasing plant flow to 18.6
MGD(plant capacity is 8.34 MGD). The first location bypassed 957,000 gallons that had received
grit and rag removal. The second location bypassed 377,000 gallons and received some first stage
secondary treatment.
April 30th(two events): Over two inches of rain fell in one hour and thirty minutes increasing the
plant flow to 18.3 MGD(plant capacity 8.34 MGD). The first location bypassed 22,300 gallons that
- 18-

had received grit and rag removal. The second location bypassed, 1/751,933 gallons and received
some first stage secondary treatment.
September 9th(two events): Six inches of rain fell in less than twenty-four hours increasing the plant
flow to 18.4 MGD(plant capacity 8.34 MGD). The first location bypassed 684 gallons that had
received grit and rag removal. The second location bypassed 1,166/000 gallons and received some
first stage secondary treatment.
December 246: Over three and one half inches of rain fell in three days with over two and one half
inches on the third day. Plant flow increased to 12,9 MGD(plant capacity 8.34 MGD). 115,117
gallons bypassed received some first stage secondary treatment. A pump failure also contributed to
this bypass.
C. Description of any known environmental impact of violations.
1. C.S.: None
2. WWTP: None
D. Description of corrective measures taken to address violations or deficiencies.
1. C.S.:
RRSD continues to performed preventative maintenance by cleaning with fetter and a
Root cutter which is attached to the Jetter hose for cutting roots,following with a CCTV
camera to inspect the lines after cleaning. The District also uses our Vac-con Truck
which cleans the line more effectively and proves to be more reliable than the old unit.
We also had our camera van upgraded to more modem technology to help us find
problems in our lines,that works well with the Vac-con truck to find infiltration in our
lines.
The District contracted with Ralph Hodge Construction to replace 162'of clay pipe with
16"ductile Iron pipe with 401 lining at 4th and Marshall St. We also replaced the
manhole in Marshall St. This was in Basin D.
MJ Price Construction and District employees together cut and cleaned 22.20 miles of outfall and
cross country lines.
District employees cleaned 31.14 miles of sewer line a CCTV all suspect problem areas.
The District contracted with JCB Construction Co.to repair 5 Manholes with Triplex Liner System.
The District contracted with Duke's Root Control to do root treatment on 4269 ft.of line in various
parts of our system.
In 2014 the District replaced our Hwy 46 West lift sta.with new Smith and Loveless Sta.
The District has secure contracts with Step Construction to repair and replace parts of Outfall G and
with Herrin-Rivenbark,Inc.to find and fix on Outfall C&D to reduce future I&I problems.
RRSD secured a planning grant from The Rural Center in 2012 to further evaluate the Belmont area.
The District employed W.K.Dickson to conduct a study including more smoke testing,manhole
evaluations and storm water dye testing to locate sources of I&I,which has been the root cause of
many reportable spills over the past few years.
- 19-

The District employees installed 31 manhole infiltration protectors in suspect area where water
floods over the manholes.
During 2014 District employees performed 12 point repairs on sewer lines.
1. 107 Harvest Rd.3' 8"PVC and install new boot for tap.
2. 201 West 8`h St.in alley 4' 8"PVC with 4"tap.
3. 104 Beechwood Rd. replaced 4' 8"PVC and 4'4"PVC for tap.
4. 119 Emery St.replaced 3' of bad sewer line.
5. 1314 Washington St.alley replaced 7' 8"Clay with 8"DSDR 35 and replaced 2 sewer
services for 1314 Washington and 1333 Jefferson St.
6.On Wyche St.at intersection of Carolina St.replaced 11' of 12"Clay with 12"PVC.
7. 1660 Hill St.replace 6'of sewer that went under storm drain with ductile.
8.Hinson and Branch St.at city shop point repair by Norlina Grading.20'401 Lined
ductile across the road.
9.At intersection of Appleton and Huntingridge Rd.replaced 9' of 8"sewer main that
had been bored through by Charter.
10.East l'`St.and Washington St.4'point repair where the gas company had bored
through the line.
11.East 2nd St.and Williams St.20'point repair made by Norlina Grading to go under
storm drains.
12. 130 Westover Dr.at Manhole 12B 6'repair made with 8"SDR back to manhole.
2. WWTP:
The WWTP is very aggressive in reacting to violations and identifying potential deficiencies. Once
identified,plans are made to upgrade or replace potential deficiencies,which may result in violation.
Modifying operations, training operators, laboratory training, improved equipment, maintenance
inventory parts and equipment and raising awareness is also an on-going and continuous process.
Some of the work done to prevent problems is the identification of potential spill areas. Once
identified,arrangements are made to stop or minimize and contain.
Several industries that discharge to the wastewater plant use chemicals that raise pH. The high pH's
could do damage to the plant in the event of a slug spill. To control this potential impact a
neutralization chemical was set up at the headworks of the plant. An old dilapidated system was
removed and a new one put back in its place. The project was begun in 2013. In 2014 the fill pipe
to the chemical tank and the first load of sulfuric acid was ordered. The wastewater plant can now
neutralize high pH's. The high pH's are detected with the use of pH monitoring system. There is
one located at the headworks. If high pH's should come in the monitoring system will send an alarm
to the main operations building. The sulfuric acid would be manually turned on to neutralize the
high pH. The monitoring system failed and had to be replaced to restore this protection.
The Rotamat removes incoming rags to prevent downstream problems. The Rotamat was scheduled
to be taken off line for some budgeted routine repairs. The unit weighs 85,000 pounds. While it was
being removed with a permanently installed gantry and hoist system, the gantry collapsed. It was
still loaded on a truck to be taken to the manufacturer for routine repairs. However, after inspection
of the Rotamat after its fall due to the gantry collapse,the additional repairs would be nearly equal to
the cost of a new unit. Although the hoist was being inspected annually by an outside contractor no
paper work could be produced demonstrating that the gantry had ever been load tested. A new
Rotamat procurement is underway.
There are two channels that direct flow into the plant. Usually only one at a time is used.
Occasionally, high flows will deposit significant amounts of sand and rock. When this happens a
vacuum truck service company will be called in to remove the debris.
-20-

The vortex grit removal system is equipped with a screw auger removal system. The bearing of the
screw auger wears and after time begins to leak wastewater. Small leaks are directed back into the
wastewater process. Before becoming uncontrollable large leaks the bearing is replaced.
Of the four Influent pumps only one of the pumps still has packing in the gland area rather than a
mechanical seal. The packing material wears and leakage begins. Although small at the beginning,
if not replaced it can become a large leak. In 2014 the fourth and last pump was retrofitted with a
mechanical seal.
Primary clarifier influent lines have grease collection pits located on them. As the pits collect grease
and fill, the flow through the influent lines can be restricted, back up, and cause spills. To prevent
this from occurring,a contracted vacuum truck company is scheduled regularly to remove the excess
grease and keep he lines unrestricted.
There are Trickling Filters each equipped with a rotary distributor. The distributor rotates spreading
wastewater evenly across the filter where it trickles down through a bed of rocks that have
microorganisms. It is the first biological treatment in the wastewater treatment system. It does some
treatment but it also "buffers" or prepares the wastewater for the next downstream biological
treatment process. Both distributors were in need of repair. The first was taken off line for repair.
During this time the remaining distributor failed. Without buffering for the subsequent biological
process the process become upset. This led to some permit violations. Both units have received the
necessary repairs and have been returned to service restoring the buffering for the subsequent
biological process. The permit violations ceased. The District met with the state to discuss options
to handle the permit violations. The length and magnitude could not be foreseen. If this could have
been foreseen the District could have requested a consent order for relaxed limitations during the
equipment repairs. Money had previously been budgeted for the repairs but it could not be
anticipated that the second unit would fail while the first was out for repair. Also, the District had
never used a consent order before so it was no forethought to request one. By the time the state
brought the use of a consent order,repairs had been completed and the plant was returning to normal
operation. In the future if the plant conditions go bad, a consent order will be thought of in a more
timely manner.
Water leaving the trickling filters enters the filter pump station where it is pumped to another
downstream process. The number of pumps used(up to four)depends on flow. During heavy rains
all four pumps are necessary. This occurred this year. The station indicator lights and the remote
SCADA monitoring indicated all four pumps were running. However, later it was discovered that
only three of the pumps were on. This contributed to a bypass that was reported. The local light and
SCADA wiring are going to be relocated to an area that will show if the pump is on or not.
Secondary clarifiers can have solids washed out during periods of high flows. Operational strategies
have been put into place to minimize this.
A permit requirement of the wastewater treatment plant is to discharge pH's in the 6-9 range. The
latter stages of the treatment process have a tendency to lower pH. For this reason the plant stores a
chemical on site to feed if pH's drop too low. The chemical used is 25%liquid sodium hydroxide
(caustic). Caustic is notorious for forming leaks at pipe joints. It can make its use dangerous
because of its corrosive nature. One of these pipe joints sprung a leak and had to be repaired so in
the event pH's got low the caustic could be safely fed.
The sodium hydroxide (caustic) used for the control of discharge pH was installed in a preexisting
building room which did not require spill containment. Liquid caustic does require spill containment
so the room was retrofitted to have containment. Caustic by nature is bad for seepage at pipe joints
and fittings. Frequent wash down is required to keep this very corrosive chemical under control.
However, since this room previously had no wash down need there is no wash down drain. To
remedy this, drains were added to the room with valves so as not to compromise the containment
area. Now the room can be kept in good and safe working condition. Because of the corrosive
nature of the caustic, the concrete wash down area was coated with a special coating which resists
the corrosiveness of the caustic and protects the concrete.
-21 -

Low influent suspended solids can occur after rains making the 85%removal difficult. Polymer can
be fed into the secondary clarifiers aiding settlement of solids and help with the 85%removal rate.
Training and directives have been put in place to prevent icing problems and equipment failure that
can result from the scum control spray system on the secondary clarifiers. This problem can also be
caused by freezing rain, sleet, and snow. Cables have also been installed to keep the equipment that
gets damaged protected.
During the construction of the disinfection/disinfection removal process, a truck unloading
containment structure was installed. The structure is piped to a pumping station equipped with pH
alarms that are tied to the SCADA system. This provides acknowledgement and control over a spill
situation that may occur during chemical delivery. The spill containment grating is open air.
Normal rain can fill the containment system. This would prevent collection in this system and a spill
could occur. Level indicators were installed on the containment system with SCADA. Now rain
water,as it accumulates,can be removed. Also,before each chemical delivery the system is pumped
down. The system is also pumped down regularly by assignment. To further control this area,the
discharge valve is kept in the closed position and the pump turned off.
The hypochlorite bulk storage tanks, which came on line in 2010, are now on an annual inspection
program. The hope is to catch a problem,preventing a catastrophic spill.
There are three anaerobic digesters located on site. They are of the floating top style. The tops are
equipped with level indicators with high level alarm. This is important due to the style. If the wrong
pump is accidently left on or some wash down water,the digesters can overflow. One of these level
indicators failed and had to be replaced to be protected from high levels in the digester.
Another of the digesters developed some cracks in the outside wall. Digester contents were slowly
starting to ooze out of the cracks. An injection company was contacted. They came in and did wall
injection with a sealant and the leakage was stopped.
A lime silo is located on site. The lime is used for waste activated solids stabilization. When a load
of lime is delivered it goes through a dust house where it is collected. The dust house had become
extremely inefficient and was replaced with a new one.
Part of the lime stabilization process includes three holding tanks used for time and pH to meet
stabilization requirement. As with a lot of other tanks and pits located at the plant,from time to time
have to be cleaned. These hold tanks are no different. Normally when the stabilization process is
complete it would take around fifteen minutes to transfer the contents out. This transfer time had
increased to an hour. A vacuum truck was called in to clean the tanks out. Along with this the drain
lines were rodded out. This restored the content removal to fifteen minutes.
During high flows or some maintenance repairs,influent flow can be diverted to equalization storage
tanks. Once flows lower or repairs are complete, the stored water is returned to the plant for
treatment. Flow is diverted to these tanks with the use of a 12 inch (5 MGD) pump. Proper
maintenance of the pump is critical. It has been rebuilt once and is on an annual preventative
maintenance contract to ensure reliability. The pump is started monthly and quarterly pumping is
done.
Two of these 12"pumps are located on the plant site. One is at the headworks for the diversion of
the incoming flow. One is located at the final treatment area to help remove outgoing flow. The
incoming pump is used very often but is getting old and losing efficiency. The outgoing flow pump
is rarely used but is newer and very efficient. Because of this the location of the two pumps was
reversed.
The plant storm water drains are blocked and gated to help control spills that might otherwise be
released from the plant site. Although painted bright yellow, they were struck and broken on
-22-

occasion. A new design keeps the containment from being easily struck. Also, flags on poles have
been added,further increasing visibility.
A valve exercise program is now employed. It keeps valves in good working order. In the event of
routine maintenance,equipment problems,or emergencies,valves used to address these issues are in
a state of readiness. As valves are repaired or replaced,they are added to the exercise list. There are
hundreds of valves located inside and outside of various areas. Each operator has a list of valves to
exercise.
Temporary pumps and hoses are used frequently. Hoses easily spring leaks. To prevent hose leaks
while pumping wastewater or biosolids,lay flat hose was replaced with reinforced canoline hose.
The plant generator is capable of powering the entire plant in the event of power loss. Without it,
spills would occur. It is on a contracted quarterly preventative maintenance program. Also, the
transfer switch which transfers incoming power to generator power is under a preventative
maintenance contract. Annually it is taken off line,disassembled,inspected,and cleaned. Without a
properly operating transfer switch, generator use is not possible. It is also exercised monthly by the
staff. And, curtailment program with the main power supply company assures further testing and
exercise of the generator.
Diesel fuel is used to run the generator. This typed of fuel can easily be contaminated. To further
ensure the reliability of the generator the fuel in the 1200 gallon storage tank is run through a filter
cleaning system on an annual basis.
The SCADA alarm system is an extremely valuable tool for preventing spills and other problems.
As problems arise or equipment fails,prompt attention is given to repairs so the alarms are returned
to service.
There are various pump station alarms throughout the plant. Some are equipped with local visual
lights and audible horns or sirens, and some are even equipped with remote SCADA alarms. In an
attempt to keep functioning alarms,they are tested on a monthly basis. As more alarms are installed,
they are added to the testing list.
Identifying and eliminating inflow and infiltration (I&I) is an on-going and difficult task. It is
important to control I&I to take excess flows off of the treatment plant. However, it is also
important to address because excess I&I "dilutes" incoming waste. With diluted wastewater it is
more difficult to meet the percent removal requirements (85%) of the plant's permit. I&I also
hydraulically over loads treatment processes making it harder to meet permit limits. In addition to
hydraulic overloads during these events, debris such as sand and rock, which has built up in the
collection system,gets flushed to the treatment plant.
The wastewater plant has a dedicated stormwater pump station strategically located in the lowest
area of the plant site. It is used only for removing rain water (melting snow) from the plant site.
This station started leaking rain water backwards into the wastewater flow. This is excess flow on
the plant that is not needed. Again a wall injection company was called. After the injection of a
sealing agent,this excess flow on the plant stopped.
The Fat,Oil,and Grease(FOG)program continues to be a useful tool for the prevention of spills. A
pretreatment technician oversees and implements the program. The technician inspects restaurants
to ensure grease trap maintenance. Best Management Practices for the control of grease entrance
into the collection system is also conveyed. Part of the FOG program is public education. The
technician is required to incorporate all users of the collection system. This is accomplished through
door hangers, bill inserts, poster distribution, advertisements, public service announcement and
public displays.
The Stormwater Pollution Prevention Plan (SPPP) is a valuable tool in identifying deficiencies. It
incorporates annual awareness and training to all plant personnel. It also requires semi-annual
inspections of all plant equipment and facilities, containment, and tanks and chemical storage. The
-23-

plan also addresses chemical suppliers and contractors through training. The plan allows for
scheduled identification of deficiencies before they become problems.
Each year during the budget process, close scrutiny is paid to the potential of deficiencies which
could lead to violations. Any identification of potential problems is addressed during this process so
that they are remedied before problems arise.
III. NOTIFICATION
A. A condensed,summarized version of this report will accompany the annual water report
which will be distributed to the users and customers of the Roanoke Rapids Sanitary
District via mail. The full report will be available at the main office upon request.
IV. CERTIFICATION
A. I certify under penalty of law that this report is complete and accurate to the best of my
knowledge. I further certify that this report has been made available to the users of the
named system and that those users have been notified of its availability.
Aile • / rigo> '276—//c
R.Danieley Brown, 'E Date
Chief Executive Officer
Reduce
Recycle
Satisfy
Develop
pKE 4.1.4
P
''O
,,„ YDTS
-24-