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Home My WebLink AboutNC0048879_Compliance Evaluation Inspection_20230622 (2)DocuSign Envelope ID: D33666E2-016E-4ED7-9C33-3664A6FCEB51 United States Environmental Protection Agency Form Approved. EPA Washington, D.C. 20460 OMB No. 2040-0057 Water Compliance Inspection Report 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 IN 1 2 u 3 I NCO048879 111 121 23/06/16 I17 18 LC] I 19 I s I 20L] 21111I I I I I I I II I I I I I I I I I I I I I I I I I I I I I I I II I I I I I r6 Inspection Work Days Facility Self -Monitoring Evaluation Rating B1 QA ---------------------- Reserved ------------------- 67 1.0 701d I 711„ I 72 I r., I 71 I 74 79 I I I I I I I80 L—I ty L-1 I I Section B: Facility Data Name and Location of Facility Inspected (For Industrial Users discharging to POTW, also include Entry Time/Date Permit Effective Date POTW name and NPDES permit Number) 09:30AM 23/06/16 19/01/01 North Cary WRF 1900 Old Reedy Creek Rd Exit Time/Date Permit Expiration Date Cary NC 27513 01:OOPM 23/06/16 23/02/28 Name(s) of Onsite Representative(s)/Titles(s)/Phone and Fax Number(s) Other Facility Data Jonathan Andrew Bulla/ORC/919-677-0850/ Name, Address of Responsible Official/Title/Phone and Fax Number Contacted Donald Bradley Smith,PO Box 8005 Cary NC 275128005//919-469-4095/9194694304 No Section C: Areas Evaluated During Inspection (Check only those areas evaluated) Permit 0 Flow Measurement Operations & Maintenar Records/Reports Self -Monitoring Progran 0 Sludge Handling Dispo: Facility Site Review Effluent/Receiving Wate Laboratory Section D: Summary of Finding/Comments (Attach additional sheets of narrative and checklists as necessary) (See attachment summary) Name(s) and Signature(s) of Inspector(s) Agency/Office/Phone and Fax Numbers Date DocuSigned by: OriATuvia DWR/NPDES WW Permitting Unit/704-663-1699/ Kevin Fowler — DWR/RRO WQ/919-791-4200/ 6/22/2023 EBB057A2DE017498... Signature of Management Q A Reviewer Agency/Office/Phone and Fax Numbers Date Vanessa E Manuel DWR/RRO WQ/919-791-4200/ 6/22/2023 EPA Form 3560-3 (Rev 9-94) Previous editions are obsoleteE�B2916EMB321441`... Docusi9ned by: &VXSSa f. t'l.aln,l, d Page# DocuSign Envelope ID: D33666E2-016E-4ED7-9C33-3664A6FCEB51 NPDES yr/mo/day Inspection Type (Cont.) NCO048879 I11 12I 23/06/16 117 18 i c i Section D: Summary of Finding/Comments (Attach additional sheets of narrative and checklists as necessary) On June 16, 2023, the DWR as conducted a compliance training inspection at the subject facility attended by: Ori Tuvia, Octovis Henriquez, Douglas Dowden, Min Xiao, Anjali Orlando, Nick coco, Fenton Brown and Kevin Fowler. The assistance of Jim Bridges and Jonathan Bulla was greatly appreciated during the inspection. Observations during the inspection are summarized below, as well as an inspection checklist is attached for your records. • The current permit expired February 28, 2023, the facility has submitted a permit renewal application in a timely manner and operates under the expired permit. The facility is permitted to discharge at a rate of 12.0 MGO and consists of: mechanical screening; influent pump station; grit and grease removal system; Nutrient removal system consisting of anaerobic selectors, oxidation ditches, anoxic zones and reaeration zones; secondary clarifiers; deep -bed sand filters; UV disinfection; cascade aeration; gravity belt thickeners; aerated sludge holding tanks. During the inspection one of the three reactor basins, one of two UV channels, and one of the three circular clarifiers were offline due to low flow. All online treatment units appeared to be operating satisfactorily. • The facility is a WW-4 Wastewater Treatment Plant and is staffed 24 hours/day 7 days a week. • Records Review: Discharge Monitoring Report records for February 2022 and February 2023 were reviewed with lab bench sheets and no transcription errors were noted. Chain of Custody forms are completed and kept on site. A daily operation log book is maintained and kept on site. Records are maintained for at least three years.- The laboratory on site is certified to analyze most permit parameters (lab cert. no. 107). Toxicity and Mercury are sent to private labs for analysis. A cursory review of the laboratory was conducted and the laboratory appeared to be properly operated. Field meter calibration records were reviewed.- Biosolids are thickened and temporarily stored on site in aerated tanks. The sludge is hauled to the South Cary WRF or Western Wake Regional WRF for aerobic digestion and thermal drying into Class A residuals.- The facility discharges to Crabtree creek, Class B, Nutrient Sensitive Waters, in the Neuse River basin. The right of way to the discharged point is maintained. The effluent was clear, trace amount of foam was observed, which dissipated within 100 feet of the outfall. No visible impacts were noted immediately downstream of the discharge point. It was noted that the receiving stream is actually an unnamed tributary to Crabtree Creek (Outfall 001 is about 100 yards away from the main channel of Crabtree Creek), the receiving stream of the facility will be revised when the permit is up for renewal. Page# DocuSign Envelope ID: D33666E2-016E-4ED7-9C33-3664A6FCEB51 Permit: NCO048879 Owner -Facility: North CaryWRF Inspection Date: 06/16/2023 Inspection Type: Compliance Evaluation Permit Yes No NA NE (If the present permit expires in 6 months or less). Has the permittee submitted a new 0 ❑ ❑ ❑ application? Is the facility as described in the permit? ❑ 0 ❑ ❑ # Are there any special conditions for the permit? M ❑ ❑ ❑ Is access to the plant site restricted to the general public? 0 ❑ ❑ ❑ Is the inspector granted access to all areas for inspection? 0 ❑ ❑ ❑ Comment: The current permit expired February 28, 2023, the facility has submitted a permit renewal application in a timely manner and operates under the expired permit. The receiving stream is actually an unnamed tributary to Crabtree Creek (Outfall 001 is about 100 yards away from the main channel of Crabtree Creek), receiving stream will be revised when the permit is up for renewal. Operations & Maintenance Yes No NA NE Is the plant generally clean with acceptable housekeeping? 0 ❑ ❑ ❑ Does the facility analyze process control parameters, for ex: MLSS, MCRT, Settleable 0 ❑ ❑ ❑ Solids, pH, DO, Sludge Judge, and other that are applicable? Comment: Facility analyzes the following parameters for process control: mixed liquor settleometer, suspended solids, pH, phosphax (PO4-P), nitratax (NOx), temperature; UV dose and flow; returned activated sludge flow; wasted sludge volume; alkalinity; and clarifier sludge blanket. Laboratory Yes No NA NE Are field parameters performed by certified personnel or laboratory? 0 ❑ ❑ ❑ Are all other parameters(excluding field parameters) performed by a certified lab? 0 ❑ ❑ ❑ # Is the facility using a contract lab? 0 ❑ ❑ ❑ # Is proper temperature set for sample storage (kept at less than or equal to 6.0 ■ ❑ ❑ ❑ degrees Celsius)? Incubator (Fecal Coliform) set to 44.5 degrees Celsius+/- 0.2 degrees? ■ ❑ ❑ ❑ Incubator (BOD) set to 20.0 degrees Celsius +/- 1.0 degrees? 0 ❑ ❑ ❑ Comment: The laboratory on site is certified to analyze most permit parameters (lab cert. no 107). Toxicity and Mercury are sent to private labs for analysis. A cursory review of the laboratory was conducted and the laboratory appeared to be properly operated. Field meter calibration records were reviewed Record Keeping Yes No NA NE Are records kept and maintained as required by the permit? 0 ❑ ❑ ❑ Is all required information readily available, complete and current? 0 ❑ ❑ ❑ Are all records maintained for 3 years (lab. reg. required 5 years)? 0 ❑ ❑ ❑ Page# 3 DocuSign Envelope ID: D33666E2-016E-4ED7-9C33-3664A6FCEB51 Permit: NCO048879 Owner -Facility: North CaryWRF Inspection Date: 06/16/2023 Inspection Type: Compliance Evaluation Record Keeping Yes No NA NE Are analytical results consistent with data reported on DMRs? 0 ❑ ❑ ❑ Is the chain -of -custody complete? 0 ❑ ❑ ❑ Dates, times and location of sampling Name of individual performing the sampling Results of analysis and calibration Dates of analysis Name of person performing analyses Transported COCs Are DMRs complete: do they include all permit parameters? ❑ ❑ ❑ Has the facility submitted its annual compliance report to users and DWQ? ❑ ❑ ❑ (If the facility is = or > 5 MGD permitted flow) Do they operate 24/7 with a certified ❑ ❑ ❑ operator on each shift? Is the ORC visitation log available and current? ❑ ❑ ❑ Is the ORC certified at grade equal to or higher than the facility classification? ❑ ❑ ❑ Is the backup operator certified at one grade less or greater than the facility ■ ❑ ❑ ❑ classification? Is a copy of the current NPDES permit available on site? 0 ❑ ❑ ❑ Facility has copy of previous year's Annual Report on file for review? ❑ ❑ ❑ Comment: Discharge Monitoring Report records for February 2022 and February 2023 were reviewed with lab bench sheets and no transcription errors were noted. Chain of Custody forms are completed and kept on site. A daily operation log book is maintained and kept on site. Records are maintained for at least three years Flow Measurement - Influent Yes No NA NE # Is flow meter used for reporting? ❑ 0 ❑ ❑ Is flow meter calibrated annually? 0 ❑ ❑ ❑ Is the flow meter operational? 0 ❑ ❑ ❑ (If units are separated) Does the chart recorder match the flow meter? ❑ ❑ ❑ Comment: Influent and effluent flow meters are calibrated twice per year. Bar Screens Yes No NA NE Type of bar screen a.Manual b.Mechanical Are the bars adequately screening debris? 0 ❑ ❑ ❑ Page# 4 DocuSign Envelope ID: D33666E2-016E-4ED7-9C33-3664A6FCEB51 Permit: NC0048879 Owner -Facility: North CaryWRF Inspection Date: 06/16/2023 Inspection Type: Compliance Evaluation Bar Screens Is the screen free of excessive debris? Is disposal of screening in compliance? Is the unit in good condition? Yes No NA NE ■ ❑ ❑ ❑ ■ ❑ ❑ ❑ ■ ❑ ❑ ❑ Comment: Two coarse screens ( 1/ 2 inch) and two fine screens ( 1/ 4 inch). Manual bar screen serves as backup. Pump Station - Influent Yes No NA NE Is the pump wet well free of bypass lines or structures? 0 ❑ ❑ ❑ Is the wet well free of excessive grease? 0 ❑ ❑ ❑ Are all pumps present? 0 ❑ ❑ ❑ Are all pumps operable? ■ ❑ ❑ ❑ Are float controls operable? 0 ❑ ❑ ❑ Is SCADA telemetry available and operational? 0 ❑ ❑ ❑ Is audible and visual alarm available and operational? ❑ ❑ ❑ Comment: Influent pump station # land # 2, each with four pumps. Grit Removal Yes No NA NE Type of grit removal a.Manual ❑ b.Mechanical Is the grit free of excessive organic matter? 0 ❑ ❑ ❑ Is the grit free of excessive odor? 0 ❑ ❑ ❑ # Is disposal of grit in compliance? 0 ❑ ❑ ❑ Comment: Grease Removal Yes No NA NE # Is automatic grease removal present? ■ ❑ ❑ ❑ Is grease removal operating properly? ■ ❑ ❑ ❑ Comment: Influent Sampling Yes No NA NE # Is composite sampling flow proportional? 0 ❑ ❑ ❑ Is sample collected above side streams? 0 ❑ ❑ ❑ Is proper volume collected? M ❑ ❑ ❑ Page# 5 DocuSign Envelope ID: D33666E2-016E-4ED7-9C33-3664A6FCEB51 Permit: NCO048879 Owner -Facility: North CaryWRF Inspection Date: 06/16/2023 Inspection Type: Compliance Evaluation Influent Sampling Yes No NA NE Is the tubing clean? 0 ❑ ❑ ❑ # 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: Comment: Flow proportional composite sample Aeration Basins Yes No NA NE Mode of operation Ext. Air Type of aeration system Diffused Is the basin free of dead spots? 0 ❑ ❑ ❑ Are surface aerators and mixers operational? 0 ❑ ❑ ❑ Are the diffusers operational? ■ ❑ ❑ ❑ Is the foam the proper color for the treatment process? 0 ❑ ❑ ❑ Does the foam cover less than 25% of the basin's surface? 0 ❑ ❑ ❑ Is the DO level acceptable? 0 ❑ ❑ ❑ Is the DO level acceptable?(1.0 to 3.0 mg/1) 0❑ ❑ ❑ Comment: Three trains of biological nutrient removal basins all trains have had a new diffuser system installed. Train A and B were on line, Train C was down due to low flow. Equalization Basins Is the basin aerated? Is the basin free of bypass lines or structures to the natural environment? Is the basin free of excessive grease? Are all pumps present? Are all pumps operable? Are float controls operable? Are audible and visual alarms operable? # Is basin size/volume adequate? Yes No NA NE • ❑ ❑ ❑ • ❑ ❑ ❑ • ❑ ❑ ❑ • ❑ ❑ ❑ ❑ ❑ ❑ ■ ❑ ❑ ❑ ■ ❑ ❑ ❑ ■ ❑ ❑ ■ ❑ Comment: EQ basins used from the old WWTP, converted from two existing clarifiers, one with aeration, an EQ pump station. Nutrient Removal # Is total nitrogen removal required? # Is total phosphorous removal required? Yes No NA NE • ❑ ❑ ❑ • ❑ ❑ ❑ Page# 6 DocuSign Envelope ID: D33666E2-016E-4ED7-9C33-3664A6FCEB51 Permit: NC0048879 Owner -Facility: North CaryWRF Inspection Date: 06/16/2023 Inspection Type: Compliance Evaluation Nutrient Removal Yes No NA NE Type Biological # Is chemical feed required to sustain process? ❑ ■ ❑ ❑ Is nutrient removal process operating properly? ■ ❑ ❑ ❑ Comment: Being converted from two existing clarifiers, one with aeration, an EQ pump station was under construction at the time of inspection Secondary Clarifier Is the clarifier free of black and odorous wastewater? Is the site free of excessive buildup of solids in center well of circular clarifier? Are weirs level? Is the site free of weir blockage? Is the site free of evidence of short-circuiting? Is scum removal adequate? Is the site free of excessive floating sludge? Is the drive unit operational? Is the return rate acceptable (low turbulence)? Is the overflow clear of excessive solids/pin floc? Is the sludge blanket level acceptable? (Approximately'/4 of the sidewall depth) Comment: Two ( A and B) of three secondary clarifiers were on line. Yes No NA NE ■ ❑ ❑ ❑ ■ ❑ ❑ ❑ ■ ❑ ❑ ❑ ■ ❑ ❑ ❑ ■ ❑ ❑ ❑ ■ ❑ ❑ ❑ ■ ❑ ❑ ❑ ■ ❑ ❑ ❑ ■ ❑ ❑ ❑ ■ ❑ ❑ ❑ ■ ❑ ❑ ❑ Pumps-RAS-WAS Yes No NA NE Are pumps in place? ■ ❑ ❑ ❑ Are pumps operational? ■ ❑ ❑ ❑ Are there adequate spare parts and supplies on site? ■ ❑ ❑ ❑ Comment: Each clarifier has a RAS- WAS pump station, with two RAS pumps and one WAS pump. Filtration (High Rate Tertiary) Yes No NA NE Type of operation: Up flow Is the filter media present? ■ ❑ ❑ ❑ Is the filter surface free of clogging? ■ ❑ ❑ ❑ Is the filter free of growth? ■ ❑ ❑ ❑ Is the air scour operational? ■ ❑ ❑ ❑ Is the scouring acceptable? ■ ❑ ❑ ❑ Is the clear well free of excessive solids and filter media? ■ ❑ ❑ ❑ Page# 7 DocuSign Envelope ID: D33666E2-016E-4ED7-9C33-3664A6FCEB51 Permit: NCO048879 Owner -Facility: North CaryWRF Inspection Date: 06/16/2023 Inspection Type: Compliance Evaluation Filtration (High Rate Tertiary) Yes No NA NE Comment: Deep - bed sand filters with 12 cells are backwshed constantly. Disinfection - UV Yes No NA NE Are extra UV bulbs available on site? 0 ❑ ❑ ❑ Are UV bulbs clean? 0 ❑ ❑ ❑ Is UV intensity adequate? ■ ❑ ❑ ❑ Is transmittance at or above designed level? ■ ❑ ❑ ❑ Is there a backup system on site? ❑ ❑ 0 ❑ Is effluent clear and free of solids? 0 ❑ ❑ ❑ Comment: One of two UV channels were in use. Each channel has capacity of 21 MGD. Flow Measurement - Effluent Yes No NA NE # Is flow meter used for reporting? 0 ❑ ❑ ❑ Is flow meter calibrated annually? 0 ❑ ❑ ❑ Is the flow meter operational? 0 ❑ ❑ ❑ (If units are separated) Does the chart recorder match the flow meter? ❑ ❑ 0 ❑ Comment: Influent and effluent flow meters are calibrated twice per year. Effluent Sampling Yes No NA NE Is composite sampling flow proportional? 0 ❑ ❑ ❑ Is sample collected below all treatment units? 0 ❑ ❑ ❑ Is proper volume collected? 0 ❑ ❑ ❑ Is the tubing clean? ■ ❑ ❑ ❑ # Is proper temperature set for sample storage (kept at less than or equal to 6.0 0 ❑ ❑ ❑ degrees Celsius)? Is the facility sampling performed as required by the permit (frequency, sampling type ❑ ❑ ❑ representative)? Comment: The subject permit requires both grab and composite samples. Effluent Pipe Yes No NA NE Is right of way to the outfall properly maintained? 0 ❑ ❑ ❑ Are the receiving water free of foam other than trace amounts and other debris? 0 ❑ ❑ ❑ If effluent (diffuser pipes are required) are they operating properly? ❑ ❑ ■ ❑ Page# 8 DocuSign Envelope ID: D33666E2-016E-4ED7-9C33-3664A6FCEB51 Permit: NC0048879 Owner -Facility: North CaryWRF Inspection Date: 06/16/2023 Inspection Type: Compliance Evaluation Effluent Pipe Comment: Upstream / Downstream Sampling Is the facility sampling performed as required by the permit (frequency, sampling type, and sampling location)? Comment: Standby Power Is automatically activated standby power available? Is the generator tested by interrupting primary power source? Is the generator tested under load? Was generator tested & operational during the inspection? Do the generator(s) have adequate capacity to operate the entire wastewater site? Is there an emergency agreement with a fuel vendor for extended run on back-up power? Is the generator fuel level monitored? Comment: Chemical Feed Is containment adequate? Is storage adequate? Are backup pumps available? Is the site free of excessive leaking? Comment: Solids Handling Equipment Is the equipment operational? Is the chemical feed equipment operational? Is storage adequate? Is the site free of high level of solids in filtrate from filter presses or vacuum filters? Is the site free of sludge buildup on belts and/or rollers of filter press? Is the site free of excessive moisture in belt filter press sludge cake? The facility has an approved sludge management plan? Yes No NA NE Yes No NA NE ■ ❑ ❑ ❑ Yes No NA NE • ❑ ❑ ❑ • ❑ ❑ ❑ • ❑ ❑ ❑ ❑ ❑ ❑ ■ ❑ ❑ ❑ ❑ ❑ ❑ ■ ■ ❑ ❑ ❑ Yes No NA NE • ❑ ❑ ❑ • ❑ ❑ ❑ • ❑ ❑ ❑ • ❑ ❑ ❑ Yes No NA NE • ❑ ❑ ❑ • ❑ ❑ ❑ • ❑ ❑ ❑ • ❑ ❑ ❑ • ❑ ❑ ❑ • ❑ ❑ ❑ • ❑ ❑ ❑ Page# 9 DocuSign Envelope ID: D33666E2-016E-4ED7-9C33-3664A6FCEB51 Permit: NCO048879 Owner -Facility: North CaryWRF Inspection Date: 06/16/2023 Inspection Type: Compliance Evaluation Solids Handling Equipment Yes No NA NE Comment: Two gravity belt thickeners dewater wasted sludge. Not in operation at the time of inspetion ( facility usually wastes sludge at night). Dewatered sludge is stored in two sludge holding tanks, and then taken to South Cary WRF or Western Wake Regional WRF for further treatment. Aerobic Digester 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: Two 0. 75 million gallon aerated sludge holding tanks. Only one was in use. Yes No NA NE ❑ ❑ ❑ ❑ ❑ ❑ ❑ ❑ ❑ ❑ ❑ ❑ ❑ ❑ ❑ Page# 10