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Home My WebLink AboutNC0025984_Compliance Evaluation Inspection_20230215 SENT VIA ELECTRONIC MAIL ONLY: NO HARD COPY WILL BE MAILED. February 15, 2023 Sonny Penson, Public Works Director Town of Forest City Email: sonnypenson@townofforestcity.com SUBJECT: Compliance Inspection Report Forest City WWTP NPDES WW Permit No. NC0025984 Rutherford County Dear Permittee: The North Carolina Division of Water Resources conducted an inspection of the Forest City WWTP on 2/07/2023. This inspection was conducted to verify that the facility is operating in compliance with the conditions and limitations specified in NPDES WW Permit No. NC0025984. The findings and comments noted during this inspection are provided in the enclosed copy of the inspection report entitled "Compliance Inspection Report". There were no significant issues or findings noted during the inspection and therefore, a response to this inspection report is not required. DocuSign Envelope ID: 5E3AC92F-8E56-4F21-832F-B64BE8485848 If you should have any questions, please do not hesitate to contact Lauren Armeni with the Water Quality Regional Operations Section in the Asheville Regional Office at 828-296-4667 or via email at lauren.armeni@ncdenr.gov. Sincerely, Daniel Boss, Assistant Regional Supervisor Water Quality Regional Operations Section Asheville Regional Office Division of Water Resources, NCDEQ ATTACHMENTS: Inspection Report Ec: Laserfiche Jacob Hodge (ORC) Caleb King (BORC) Tommy Wilson (BORC) DocuSign Envelope ID: 5E3AC92F-8E56-4F21-832F-B64BE8485848 EPA United States Environmental Protection Agency Washington, D.C. 20460 Water Compliance Inspection Report Form Approved. OMB No. 2040-0057 Approval expires 8-31-98 Section A: National Data System Coding (i.e., PCS) Transaction Code NPDES yr/mo/day Inspection Type Inspector Fac Type 1 N 52 NC0025984 23/02/07 C S31112171819 20 21 66 Inspection Work Days Facility Self-Monitoring Evaluation Rating B1 QA ----------------------Reserved------------------- N67707172 73 74 75 80 Section B: Facility Data Name and Location of Facility Inspected (For Industrial Users discharging to POTW, also include POTW name and NPDES permit Number) Forest City WWTP 397 Riverside Dr Forest City NC 28043 Entry Time/Date Permit Effective Date Exit Time/Date Permit Expiration Date 10:00AM 23/02/07 21/12/01 Name(s) of Onsite Representative(s)/Titles(s)/Phone and Fax Number(s) /// Jacob William Hodge/ORC/828-248-5217/ Other Facility Data 01:00PM 23/02/07 26/07/31 Name, Address of Responsible Official/Title/Phone and Fax Number Sonny Penson,PO Box 728 Forest City NC 280430728//828-248-5217/8282474626 Contacted No Section C: Areas Evaluated During Inspection (Check only those areas evaluated) Permit Flow Measurement Operations & Maintenance Records/Reports Self-Monitoring Program Sludge Handling Disposal Facility Site Review Effluent/Receiving Waters Section D: Summary of Finding/Comments (Attach additional sheets of narrative and checklists as necessary) (See attachment summary) Name(s) and Signature(s) of Inspector(s)Agency/Office/Phone and Fax Numbers Date Lauren E Armeni DWR/ARO WQ/828-296-4500/ Mara G Chamlee DWR/ARO WQ/828-296-4500/ Signature of Management Q A Reviewer Agency/Office/Phone and Fax Numbers Date EPA Form 3560-3 (Rev 9-94) Previous editions are obsolete. Page#1 DocuSign Envelope ID: 5E3AC92F-8E56-4F21-832F-B64BE8485848 2/16/2023 2/16/2023 2/16/2023 NPDES yr/mo/day 23/02/07 Inspection Type C3111218 1 Section D: Summary of Finding/Comments (Attach additional sheets of narrative and checklists as necessary) Lauren Armeni and Mara Chamlee, with the Asheville Regional Office, conducted a compliance evaluation inspection of the Town of Forest City's WWTP on February 7, 2023. This inspection was conducted to determine whether the facility is being operated and maintained in compliance with the NPDES Permit No. NC0025984. Jacob Hodge (ORC), Tommy Wilson (Plant Supervisor/BORC), Caleb King (Lab Analyst/BORC), and Seth Hollars (Operator) were present and assisted in the inspection. Overall, the facility was well-maintained and operated. All paperwork was organized and readily accessible. The following items were noted during the inspection. Aeration Basins: The facility has approximately six aeration basins, but only one is currently in use. The other basins would need to be refurbished and repaired before placed into operation. The basin in use can accommodate approximately 4 MG. The settleometer read 999 mL after 30 minutes of settling time, which is unusual and could indicate that there are too many solids throughout the plant, and solids management may need to be evaluated. DO read 1.8 mg/L at the time of inspection. Facility staff noted that they generally read DO at the effluent, but indicated that they will begin reading DO at the aeration basin as well. Secondary Clarifiers: The telescoping valve is still broken, and it is recommended that it be repaired to help staff more easily and effectively operate the plant. Standby Power: It is still recommended that during future plant upgrades, the aeration basin surface aerators be connected to the generator to prevent an upset during an extended power outage. NC0025984 17 (Cont.) Page#2 DocuSign Envelope ID: 5E3AC92F-8E56-4F21-832F-B64BE8485848 Permit:NC0025984 Inspection Date:02/07/2023 Owner - Facility: Inspection Type: Forest City WWTP Compliance Evaluation Permit Yes No NA NE (If the present permit expires in 6 months or less). Has the permittee submitted a new application? Is the facility as described in the permit? # Are there any special conditions for the permit? Is access to the plant site restricted to the general public? Is the inspector granted access to all areas for inspection? Comment: Operations & Maintenance Yes No NA NE Is the plant generally clean with acceptable housekeeping? Does the facility analyze process control parameters, for ex: MLSS, MCRT, Settleable Solids, pH, DO, Sludge Judge, and other that are applicable? Process controls analyzed include MLSS, DO, and routine checks of the sludge blanket. Comment: Record Keeping Yes No NA NE Are records kept and maintained as required by the permit? Is all required information readily available, complete and current? Are all records maintained for 3 years (lab. reg. required 5 years)? Are analytical results consistent with data reported on DMRs? Is the chain-of-custody complete? Dates, times and location of sampling Name of individual performing the sampling Results of analysis and calibration Dates of analysis Name of person performing analyses Transported COCs Are DMRs complete: do they include all permit parameters? Has the facility submitted its annual compliance report to users and DWQ? (If the facility is = or > 5 MGD permitted flow) Do they operate 24/7 with a certified operator on each shift? Is the ORC visitation log available and current? Is the ORC certified at grade equal to or higher than the facility classification? Is the backup operator certified at one grade less or greater than the facility classification? Page#3 DocuSign Envelope ID: 5E3AC92F-8E56-4F21-832F-B64BE8485848 Permit:NC0025984 Inspection Date:02/07/2023 Owner - Facility: Inspection Type: Forest City WWTP Compliance Evaluation Record Keeping Yes No NA NE Is a copy of the current NPDES permit available on site? Facility has copy of previous year's Annual Report on file for review? Annual Reports are generated for both the CS and WWTP and posted on the Town's website. Staff analyze most of the permit parameters in-house. Metals, pollutant scans, and toxicity are contracted out to Environmental Testing Solutions. Comment: Flow Measurement - Influent Yes No NA NE # Is flow meter used for reporting? Is flow meter calibrated annually? Is the flow meter operational? (If units are separated) Does the chart recorder match the flow meter? Flow meters are calibrated twice a year by KDT Service Technologies. The flow meter was last calibrated on January 17, 2023. Comment: Influent Sampling Yes No NA NE # Is composite sampling flow proportional? Is sample collected above side streams? Is proper volume collected? Is the tubing clean? # Is proper temperature set for sample storage (kept at less than or equal to 6.0 degrees Celsius)? Is sampling performed according to the permit? Comment: Bar Screens Yes No NA NE Type of bar screen a.Manual b.Mechanical Are the bars adequately screening debris? Is the screen free of excessive debris? Is disposal of screening in compliance? Is the unit in good condition? The mechanical bar screen was replaced in 2021 with the same model as the old screen. The old screen was refurbished and is kept as a backup. Comment: Page#4 DocuSign Envelope ID: 5E3AC92F-8E56-4F21-832F-B64BE8485848 Permit:NC0025984 Inspection Date:02/07/2023 Owner - Facility: Inspection Type: Forest City WWTP Compliance Evaluation Grit Removal Yes No NA NE Type of grit removal a.Manual b.Mechanical Is the grit free of excessive organic matter? Is the grit free of excessive odor? # Is disposal of grit in compliance? The grit chamber is currently not operational, but continues to be aerated. Currently, grit is pumped out and disposed of by Harris Septic. Facility staff indicated that they are waiting on bids to get the grit chamber refurbished, and plan to have it completed this year. Comment: Grease Removal Yes No NA NE # Is automatic grease removal present? Is grease removal operating properly? Grease is pumped from the headworks as needed by Harris Septic and is land applied under a DWM permit. Automatic grease removal is present, but not in use. Comment: Aeration Basins Yes No NA NE Mode of operation Ext. Air Type of aeration system Surface Is the basin free of dead spots? Are surface aerators and mixers operational? Are the diffusers operational? Is the foam the proper color for the treatment process? Does the foam cover less than 25% of the basin’s surface? Is the DO level acceptable? Is the DO level acceptable?(1.0 to 3.0 mg/l) The facility has approximately six aeration basins, but only one is currently in use. One out-of-service basin is used as an equalization basin and one is used as a return sludge backup. According to staff, DO is typically between 1.6-1.8 mg/L in the summer and 4-5 mg/L in the winter. At the time of inspection, DO was 1.8 mg/L, and Mr. Hodge indicated MLSS was around 4,500 mg/L. See summary for details. Comment: Secondary Clarifier Yes No NA NE Is the clarifier free of black and odorous wastewater? Is the site free of excessive buildup of solids in center well of circular clarifier? Are weirs level? Page#5 DocuSign Envelope ID: 5E3AC92F-8E56-4F21-832F-B64BE8485848 Permit:NC0025984 Inspection Date:02/07/2023 Owner - Facility: Inspection Type: Forest City WWTP Compliance Evaluation Secondary Clarifier Yes No NA NE Is the site free of weir blockage? Is the site free of evidence of short-circuiting? Is scum removal adequate? Is the site free of excessive floating sludge? Is the drive unit operational? Is the return rate acceptable (low turbulence)? Is the overflow clear of excessive solids/pin floc? Is the sludge blanket level acceptable? (Approximately ¼ of the sidewall depth) Facility staff reported that due to the diameter of the secondary effluent pipe, the clarifiers back-up during heavy flow events. The telescopic return valve in the clarifier is broken and should be fixed to help staff more easily manage and operate the facility. Clarifier #1 had a blanket of approximately 5' out of 14.5' and Clarifier #2 had a blanket of approximately 4' out of 14.5'. Sludge blankets are somewhat high, and solids management may need to be evaluated. The scum arm on Clarifier #2 did not appear to remove scum efficiently; however, Mr. Hodge indicated that they would be replacing it soon. Comment: Pumps-RAS-WAS Yes No NA NE Are pumps in place? Are pumps operational? Are there adequate spare parts and supplies on site? Staff indicated that there are two pumps each for RAS & WAS, which are alternated every six months; therefore, an alternate pump is always available. Mr. Hodge indicated that the check valve leaks for one of the return sludge pumps, and the valve will be replaced this year. Comment: Disinfection-Gas Yes No NA NE Are cylinders secured adequately? Are cylinders protected from direct sunlight? Is there adequate reserve supply of disinfectant? Is the level of chlorine residual acceptable? Is the contact chamber free of growth, or sludge buildup? Is there chlorine residual prior to de-chlorination? Does the Stationary Source have more than 2500 lbs of Chlorine (CAS No. 7782-50-5)? If yes, then is there a Risk Management Plan on site? If yes, then what is the EPA twelve digit ID Number? (1000-____-____) Page#6 DocuSign Envelope ID: 5E3AC92F-8E56-4F21-832F-B64BE8485848 Permit:NC0025984 Inspection Date:02/07/2023 Owner - Facility: Inspection Type: Forest City WWTP Compliance Evaluation Disinfection-Gas Yes No NA NE If yes, then when was the RMP last updated? The Town maintains no more than 2,500 lbs of chlorine at one time. Currently, staff are feeding approximately 10-12lbs per day of chlorine. Mr. Hodge indicated that they plan to switch to a digital feed this year or next. He also indicated that the contact chamber is aerated in the summer to keep DO up. Disinfection is still flow-proportional. Comment: De-chlorination Yes No NA NE Type of system ?Gas Is the feed ratio proportional to chlorine amount (1 to 1)? Is storage appropriate for cylinders? # Is de-chlorination substance stored away from chlorine containers? Are the tablets the proper size and type? Sulfur dioxide containers are stored in the same building as the chlorine cylinders.Comment: Are tablet de-chlorinators operational? Number of tubes in use? Comment: Flow Measurement - Effluent Yes No NA NE # Is flow meter used for reporting? Is flow meter calibrated annually? Is the flow meter operational? (If units are separated) Does the chart recorder match the flow meter? Flow meters are calibrated twice a year by KDT Service Technologies. At the time of inspection, the most recent calibration was performed on January 17, 2023. Comment: Effluent Sampling Yes No NA NE Is composite sampling flow proportional? Is sample collected below all treatment units? Is proper volume collected? Is the tubing clean? # Is proper temperature set for sample storage (kept at less than or equal to 6.0 degrees Celsius)? Is the facility sampling performed as required by the permit (frequency, sampling type representative)? Comment: Page#7 DocuSign Envelope ID: 5E3AC92F-8E56-4F21-832F-B64BE8485848 Permit:NC0025984 Inspection Date:02/07/2023 Owner - Facility: Inspection Type: Forest City WWTP Compliance Evaluation Effluent Pipe Yes No NA NE Is right of way to the outfall properly maintained? Are the receiving water free of foam other than trace amounts and other debris? If effluent (diffuser pipes are required) are they operating properly? Comment: Standby Power Yes No NA NE Is automatically activated standby power available? Is the generator tested by interrupting primary power source? Is the generator tested under load? Was generator tested & operational during the inspection? Do the generator(s) have adequate capacity to operate the entire wastewater site? Is there an emergency agreement with a fuel vendor for extended run on back-up power? Is the generator fuel level monitored? The generator can run everything except for the blower motors. Facility staff keep approximately 500 gallons of diesel fuel on site. Staff indicated that the generator automatically exercises every Thursday for 30 minutes. The generator is maintained by Power Generator once a year. See summary for details. Comment: Aerobic Digester Yes No NA NE Is the capacity adequate? Is the mixing adequate? Is the site free of excessive foaming in the tank? # Is the odor acceptable? # Is tankage available for properly waste sludge? Both digesters are now operational again. Staff indicated that they waste approximately five to six hours a week. Decant from the digesters goes to the aeration basin. Sludge is pumped from Digester #1 to the rotary drum thickener, to Digester #2, and then to the belt filter press. Comment: Solids Handling Equipment Yes No NA NE Is the equipment operational? Is the chemical feed equipment operational? Is storage adequate? Is the site free of high level of solids in filtrate from filter presses or vacuum filters? Is the site free of sludge buildup on belts and/or rollers of filter press? Page#8 DocuSign Envelope ID: 5E3AC92F-8E56-4F21-832F-B64BE8485848 Permit:NC0025984 Inspection Date:02/07/2023 Owner - Facility: Inspection Type: Forest City WWTP Compliance Evaluation Solids Handling Equipment Yes No NA NE Is the site free of excessive moisture in belt filter press sludge cake? The facility has an approved sludge management plan? The drain in the drum thickener room goes back to headworks. Runoff from the belt press goes to the splitter box. US Biosolids picks up sludge from the facility and is land applied through their permit. The Operations and Maintenance Plan from US Biosolids is kept on site. The belt press has still not been updated as faciltity staff are waiting on parts. Mr. Hodge indicated that the sludge pump and conveyor belt will be replaced this year. Comment: Page#9 DocuSign Envelope ID: 5E3AC92F-8E56-4F21-832F-B64BE8485848