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Home My WebLink AboutNC0040797_Inspection_20190124 (2)ROY COOPER Governor MICHAEL S. REGAN Secretary LINDA CULPEPPER Director Mr. Shawn Pennell Assistant Public Services Director/Public Utilities City of Hickory Post Office Box 398 Hickory, North Carolina 28603 Dear Mr. Pennell: NORTH CAROLINA Environmental Quality 24 January 2019 Subject: Compliance Evaluation Inspection City of Hickory/Henry Fork WWTP NPDES Permit No. NCO040797 Catawba County Enclosed is a copy of the Compliance Evaluation Inspection Report for the inspection conducted at the subject facility on January 17, 2019, by Mr. Wes Bell of this Office. Please inform the facility's Operator -in -Responsible Charge (ORC) of our findings by forwarding a copy of the enclosed report. The report should be self-explanatory; however, should you have any questions concerning this report, please do not hesitate to contact Mr. Bell at (704) 235-2192 or at wes.bell@ncdenr.gov. Sincerely, DocuSigned by: A14CC681 AF27425... W. Corey Basinger, Regional Supervisor Water Quality Regional Operations Section Division of Water Resources, NCDEQ Enclosure: Inspection Report D Q North Carolina Department of Environmental Quality I Division of Water Resources Mooresville Regional Office 1 610 East Center Avenue, Suite 301 1 Mooresville, North Carolina 28115 NORTH CAROLINA Da"MoM a enWmn bl mwnq 704,663.1699 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 NC0040797 19/01/17 C S31112171819 20 21 66 Inspection Work Days Facility Self-Monitoring Evaluation Rating B1 QA ----------------------Reserved------------------- 2.0 4 N 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) Henry Fork WWTP 4014 River Rd Hickory NC 28602 Entry Time/Date Permit Effective Date Exit Time/Date Permit Expiration Date 09:20AM 19/01/17 18/09/01 Name(s) of Onsite Representative(s)/Titles(s)/Phone and Fax Number(s) /// Robert P Shaver/ORC/828-294-0861/ Other Facility Data 11:25AM 19/01/17 22/07/31 Name, Address of Responsible Official/Title/Phone and Fax Number Shawn Pennell,PO Box 398 Hickory NC 286010398/Asst. Public Services Manager/828-323-7427/8283221405 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 Wes Bell DWR/MRO WQ/704-663-1699 Ext.2192/ Signature of Management Q A Reviewer Agency/Office/Phone and Fax Numbers Date W. Corey Basinger DWR/Division of Water Quality/704-235-2194/ EPA Form 3560-3 (Rev 9-94) Previous editions are obsolete. Page#1 NPDES yr/mo/day 19/01/17 Inspection Type C3111218 1 Section D: Summary of Finding/Comments (Attach additional sheets of narrative and checklists as necessary) NC0040797 17 Page#2 Permit:NC0040797 Inspection Date:01/17/2019 Owner - Facility: Inspection Type: Henry Fork 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? The last compliance evaluation inspection by DWR staff was performed on 1/27/17.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? Is a copy of the current NPDES permit available on site? Facility has copy of previous year's Annual Report on file for review? The records reviewed during the inspection were organized and well maintained. Discharge Monitoring Reports (edmrs) were reviewed for the period December 2017 through November 2018. A chronic toxicity failure was reported in February 2018; however, the facility passed to the follow-up multi-range toxicity tests. The facility complied with all permit-required monitoring frequencies. Comment: Page#3 Permit:NC0040797 Inspection Date:01/17/2019 Owner - Facility: Inspection Type: Henry Fork WWTP Compliance Evaluation 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)? Incubator (Fecal Coliform) set to 44.5 degrees Celsius+/- 0.2 degrees? Incubator (BOD) set to 20.0 degrees Celsius +/- 1.0 degrees? Influent and effluent analyses (including field) are performed under the City of Hickory’s Regional Laboratory Certification #203. Pace Analytical Services (metals, PPA), Statesville Analytical (color), R&A Labs (chlorophyll-a), and Blue Ridge Labs (cyanide) have also been contracted to provide analytical support. 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? The subject permit requires influent BOD and TSS composite samples. The facility has recently initiated the collection of time-based composite samples due to continued operational problems associated with the influent flow measurement system. This office approved the facility’s emailed request (dated 1/18/19) to collect time-based influent composite samples during the repair/replacement of the influent flow measurement system. The approval was issued on 1/23/19 (via email) and will allow the collection of time-based influent composite samples for thirty (30) days. The influent sampler was collecting 125 ml. aliquots and the internal ambient sampler temperature was one degree Celsius at the time of the inspection. 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)? Page#4 Permit:NC0040797 Inspection Date:01/17/2019 Owner - Facility: Inspection Type: Henry Fork WWTP Compliance Evaluation Effluent Sampling Yes No NA NE The subject permit requires composite and grab effluent samples. The influent and effluent samplers are checked daily and monthly aliquot calibrations/verifications are performed and documented. The effluent sampler was collecting 160 ml. aliquots and the internal ambient sampler temperature was approximately one degree Celsius. Comment: Upstream / Downstream Sampling Yes No NA NE Is the facility sampling performed as required by the permit (frequency, sampling type, and sampling location)? 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? The wastewater treatment facility appeared to be properly operated and well maintained. The ORC and staff implement a comprehensive process control program with all measurements being properly documented and maintained on-site. The facility is equipped with a SCADA system to assist the wastewater staff with the facility’s operations. The facility was currently using one primary clarifier and one aeration basin and chlorine contact chamber train due to low influent flows. 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: Pump Station - Influent Yes No NA NE Is the pump wet well free of bypass lines or structures? Is the wet well free of excessive grease? Are all pumps present? Are all pumps operable? Page#5 Permit:NC0040797 Inspection Date:01/17/2019 Owner - Facility: Inspection Type: Henry Fork WWTP Compliance Evaluation Pump Station - Influent Yes No NA NE Are float controls operable? Is SCADA telemetry available and operational? Is audible and visual alarm available and operational? 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? # Is disposal of grit in compliance? Screenings and grit are disposed at the County Landfill.Comment: Equalization Basins Yes No NA NE 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? Comment: Primary 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? Page#6 Permit:NC0040797 Inspection Date:01/17/2019 Owner - Facility: Inspection Type: Henry Fork WWTP Compliance Evaluation Primary Clarifier Yes No NA NE Is the drive unit operational? Is the sludge blanket level acceptable? Is the sludge blanket level acceptable? (Approximately ¼ of the sidewall depth) Both primary clarifiers were operational.Comment: Aeration Basins Yes No NA NE Mode of operation Ext. Air Type of aeration system Diffused 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) Both aeration basin trains were operational. Magnesium hydroxide is added to maintain appropriate alkalinity/pH levels. Comment: Chemical Feed Yes No NA NE Is containment adequate? Is storage adequate? Are backup pumps available? Is the site free of excessive leaking? 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? Page#7 Permit:NC0040797 Inspection Date:01/17/2019 Owner - Facility: Inspection Type: Henry Fork WWTP Compliance Evaluation Secondary Clarifier Yes No NA NE 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) Both secondary clarifiers were operational and in service.Comment: Pumps-RAS-WAS Yes No NA NE Are pumps in place? Are pumps operational? Are there adequate spare parts and supplies on site? 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-____-____) If yes, then when was the RMP last updated? 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? Comment: Are the tablets the proper size and type? Are tablet de-chlorinators operational? Page#8 Permit:NC0040797 Inspection Date:01/17/2019 Owner - Facility: Inspection Type: Henry Fork WWTP Compliance Evaluation De-chlorination Yes No NA NE 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? The flow meter is calibrated twice per year and was last calibrated on 7/17/18 by Diversified Integration, Inc. 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? The effluent appeared clear with no floatable solids or foam.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? The primary clarifier sludge and waste activated sludge are pumped into separate storage tanks. Primary and waste activated sludges are transported to the Regional Compost facility for further treatment and disposal. 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? Page#9 Permit:NC0040797 Inspection Date:01/17/2019 Owner - Facility: Inspection Type: Henry Fork WWTP Compliance Evaluation Standby Power Yes No NA NE Is the generator fuel level monitored? Both standby generators are checked daily and placed under load monthly.Comment: Page#10