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Home My WebLink AboutNC0065102_Compliance Evaluation Inspection_20230224 North Carolina Department of Environmental Quality Division of Water Resources Raleigh Regional Office 3800 Barrett Drive Raleigh, North Carolina 27609 919.791.4200 February 24, 2023 Jamie Revels Town of Cary PO Box 8005 Cary, NC 27512 Subject: NPDES Compliance Evaluation Inspection South Cary Water Reclamation Facility NPDES Permit No. NC0065102 Wake County Dear Mr. Revels: On February 20, 2023, Stephanie Goss of the Raleigh Regional Office (RRO), conducted an inspection at the subject facility. The cooperation of Jarrod Buchanan, Josh Cummings, and Jenny Exum was greatly appreciated. Findings during the inspection were as follows: 1. The current NPDES permit was issued effective on October 19, 2018 and expires on April 30, 2023. The Division is in the process of renewing this NPDES permit. The renewal application was received on October 17, 2022. 2. The WW-4 facility is permitted to treat 12.8 MGD of treated wastewater and consists of the following components: two automatic bar screens, one manual bar screen, influent flow meter, two aerated grit chambers, three five-stage BNR reactor basins with aerobic, anoxic, and anaerobic zones, four secondary clarifiers, seven deep bed tertiary filters, ultraviolet disinfection, effluent flow meter, effluent composite sampler, two gravity belt thickeners, biosolids aerated holding tanks, two liquid solids loading and receiving stations, two dewatering centrifuges, one biosolids rotary drum dryer, two pelletized biosolids storage silos, and four back up power generators. 3. The plant discharges to the Middle Creek, which is classified as Class C, Nutrient Sensitive Waters in the Neuse River Basin. 4. The influent flow meter is calibrated twice a year and was calibrated on February 14, 2023, by Citi, LLC. 5. The refrigerated influent and effluent units were maintained at the proper temperature, < 6 degrees C. The effluent composite sampler is programmed flow proportionally. DocuSign Envelope ID: D26A7219-7677-4993-9DAF-D81D4F4FABCF North Carolina Department of Environmental Quality Division of Water Resources Raleigh Regional Office 3800 Barrett Drive Raleigh, North Carolina 27609 919.791.4200 Page 2 of 3 6. At the time of the inspection, two of the three BNR reactor basins, #1 and #2, were in operation. The two basins appeared to be operating satisfactorily. There was foam on approximately 70% of the surface of each basin. 7. At the time of the inspection, clarifiers #1, #2 and #4 were in operation. The clarifiers appeared to be operating satisfactorily. The overflow weirs were covered and were not able to be observed during the inspection. A sludge judge on clarifier #1 showed the sludge depth to be approximately three feet deep with the depth of the clarifier to be fourteen feet, a sludge judge on clarifier #2 showed the sludge depth to be approximately three feet deep with the depth of the clarifier to be fourteen feet, and s sludge judge on clarifier #4 showed the sludge depth to be approximately two feet deep with the depth of the clarifier to be fourteen feet. 8. The deep bed tertiary filters appeared to be operating satisfactorily. The filtered effluent appeared clear and free of solids. 9. The one-channel ultraviolet disinfection system with dual banks was in operation during the inspection and appeared to be operating satisfactorily. The bulbs are changed out as needed and each bank is rotated for usage every six months. The facility keeps multiple spare bulbs in storage near the ultraviolet system. 10. The effluent flow meter was calibrated on February 14, 2023 and is calibrated twice a year with Citi, LLC. 11. The post aeration system was operating satisfactorily. The effluent was clear and free of excess solids. 12. Mr. Buchanan stated the waste activated sludge is removed from the clarifiers and is sent to the biosolids aerated holding tanks. 1A, 1B, and 1C digestors were in use at the time of the inspection. The sludge is kept in the aerated holding tanks for approximately seven days then dewatered in the centrifuges and thermal dried in the biosolids dryer. The sludge is then turned into pellets which is considered Class A sludge. 13. Mr. Buchanan stated the four onsite diesel generators are tested weekly and tested under load annually. 14. A review of discharge monitoring report (DMR) data for the period March 2021 through December 2022 showed all required monitoring was performed and that the facility complied with all permit limits. 15. A cursory review of laboratory and DMR data for February 2022 showed consistent reporting of results. 16. A cursory review of calibration logs showed acceptable calibration for the on-site parameters. DocuSign Envelope ID: D26A7219-7677-4993-9DAF-D81D4F4FABCF North Carolina Department of Environmental Quality Division of Water Resources Raleigh Regional Office 3800 Barrett Drive Raleigh, North Carolina 27609 919.791.4200 Page 3 of 3 17. Mr. Buchanan stated there are no industries that discharge to the Town on South Cary Water Reclamation Facility. 18. The effluent discharge appeared free of excess solids. No detrimental impacts to Middle Creek were observed. 19. An operator logbook is kept detailing plant operations, problems, and routine cleaning. 20. The Town of Cary handles the Annual Compliance Report for South Cary Water Reclamation Facility every year. Mr. Buchanan stated that he submits his data to the Town every year in July. The facility is compliant with the NPDES permit conditions as a result of this inspection. The plant is well maintained, very clean and the ORC’s attention to detail is commendable. If you have questions concerning this report, please contact Stephanie Goss at 919-791-4256 or Stephanie.goss@ncdenr.gov. Sincerely, Vanessa E. Manuel, Assistant Regional Supervisor Water Quality Regional Operations Section Raleigh Regional Office Division of Water Resources, NCDEQ cc: Laserfiche DocuSign Envelope ID: D26A7219-7677-4993-9DAF-D81D4F4FABCF 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 NC0065102 23/02/20 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) South Cary WRF 4900 W Lk Rd Apex NC 27539 Entry Time/Date Permit Effective Date Exit Time/Date Permit Expiration Date 09:30AM 23/02/20 18/12/01 Name(s) of Onsite Representative(s)/Titles(s)/Phone and Fax Number(s) /// Joseph Craig Cummings/ORC/919-779-0697/ Other Facility Data 11:45PM 23/02/20 23/04/30 Name, Address of Responsible Official/Title/Phone and Fax Number Jarrod Buchanan,4900 W Lake Rd Apex NC 275398005//919-779-0697/9196628118 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 Laboratory Section D: Summary of Finding/Comments (Attach additional sheets of narrative and checklists as necessary) (See attachment summary) Name(s) and Signature(s) of Inspector(s)Agency/Office/Phone and Fax Numbers Date Stephanie Goss DWR/RRO WQ/919-791-4200/ 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 2/24/2023 DocuSign Envelope ID: D26A7219-7677-4993-9DAF-D81D4F4FABCF 2/26/2023 NPDES yr/mo/day 23/02/20 Inspection Type C3111218 1 Section D: Summary of Finding/Comments (Attach additional sheets of narrative and checklists as necessary) NC0065102 17 Page#2 DocuSign Envelope ID: D26A7219-7677-4993-9DAF-D81D4F4FABCF Permit:NC0065102 Inspection Date:02/20/2023 Owner - Facility: Inspection Type: South Cary WRF Compliance Evaluation Operations & Maintenance Yes No NA NE Is the plant generally clean with acceptable housekeeping? Does the facility analyze process control parameters, for ex: MLSS, MCRT, Settleable Solids, pH, DO, Sludge Judge, and other that are applicable? Comment: 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: 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: D26A7219-7677-4993-9DAF-D81D4F4FABCF Permit:NC0065102 Inspection Date:02/20/2023 Owner - Facility: Inspection Type: South Cary WRF 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? Comment: 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: 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? 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? Comment: 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? Page#4 DocuSign Envelope ID: D26A7219-7677-4993-9DAF-D81D4F4FABCF Permit:NC0065102 Inspection Date:02/20/2023 Owner - Facility: Inspection Type: South Cary WRF Compliance Evaluation Grit Removal Yes No NA NE # Is disposal of grit in compliance? 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? 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) 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)? Tubing was slightly dirty. Recommended that the tubing be replaced and to replace on a regular basis. Comment: Laboratory Yes No NA NE Are field parameters performed by certified personnel or laboratory? Are all other parameters(excluding field parameters) performed by a certified lab? # Is the facility using a contract lab? # Is proper temperature set for sample storage (kept at less than or equal to 6.0 degrees Celsius)? Page#5 DocuSign Envelope ID: D26A7219-7677-4993-9DAF-D81D4F4FABCF Permit:NC0065102 Inspection Date:02/20/2023 Owner - Facility: Inspection Type: South Cary WRF Compliance Evaluation Laboratory Yes No NA NE Incubator (Fecal Coliform) set to 44.5 degrees Celsius+/- 0.2 degrees? Incubator (BOD) set to 20.0 degrees Celsius +/- 1.0 degrees? Comment: Sand Filters (Low rate)Yes No NA NE (If pumps are used) Is an audible and visible alarm Present and operational? Is the distribution box level and watertight? Is sand filter free of ponding? Is the sand filter effluent re-circulated at a valid ratio? # Is the sand filter surface free of algae or excessive vegetation? # Is the sand filter effluent re-circulated at a valid ratio? (Approximately 3 to 1) 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? 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? Comment: Aeration Basins Yes No NA NE Page#6 DocuSign Envelope ID: D26A7219-7677-4993-9DAF-D81D4F4FABCF Permit:NC0065102 Inspection Date:02/20/2023 Owner - Facility: Inspection Type: South Cary WRF Compliance Evaluation Aeration Basins Yes No NA NE Mode of operation Type of aeration system 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) Foam covered approx. 70% of the aeration basin.Comment: Disinfection - UV Yes No NA NE Are extra UV bulbs available on site? Are UV bulbs clean? Is UV intensity adequate? Is transmittance at or above designed level? Is there a backup system on site? Is effluent clear and free of solids? Comment: Page#7 DocuSign Envelope ID: D26A7219-7677-4993-9DAF-D81D4F4FABCF