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Home My WebLink AboutNC0020559_Compliance Evaluation Inspection_20230705DocuSign Envelope ID: EF459FA9-340D-4FEC-B116-E0492F828D05 ROY COOPER Governor ELIZABETH S. BISER Secretary RICHARD E. ROGERS, JR. Director Mr. Terrell Blackmon City Manager City of Henderson P.O. Box 1434 Henderson, NC 27536 NORTH CAROLINA Environmental Quality July 5, 2023 Subject: Compliance Evaluation Inspection Henderson Water Reclamation Facility NPDES Permit No. NCO020559 Vance County Dear Mr. Blackmon: On June 7, 2023, Cheng Zhang and Kevin Fowler of the Raleigh Regional Office (RRO) conducted a compliance evaluation inspection of the subject facility. The assistance provided by Ms. Christy Lipscombe, the operator in responsible charge (ORC), and Mr. Brandon Elliott, the backup ORC, was greatly appreciated as it facilitated the inspection process. The inspection report is attached. The following observations were made: Henderson Water Reclamation Facility is permitted to discharge at a rate of 4.14 MGD and consists of. influent pump station; dual bar screens; grit removal system; biological nutrient removal system — 4 anaerobic basins, 2 anoxic zones, 2 oxidation ditches with 4 aerators ( 100 HP); two secondary clarifiers; UV disinfection with sodium hypochlorite backup; four (4) tertiary sand filters; post aeration; aerobic digester; sludge holding tank; waste activated sludge pumps, screw thickener; and screw thickener discharge pump. The facility discharges into Nutbush Creek, which is classified C waters in the Roanoke River Basin. 1. The current permit expired on March 31, 2023. Renewal application was received by the Division on November 28, 2022. 2. At the time of inspection, the following treatment units were not in used due to low flow: one of two BNR ditches, and two of four tertiary filters. Color of the influent in the oxidation ditch appeared chocolate brown. Foam covered about 50% of the basin. Effluent flowing at the weirs of the secondary clarifier and clear well of the tertiary sand filters appeared clear. Sludge blankets in the secondary clarifiers were less than a foot. The screw thickener was in operation at the time of inspection. The aerobic digester was about 3/4 full. 3. Lab results, chain -of -custody forms, and DMRs were complete and current, kept in good order and ready for review. July 2022 and January 2023 DMR data were compared to lab bench sheets and laboratory reports; no data transcription errors were noted. North Carolina Department of Environmental Quality I Division of Water Resources Raleigh Regional Office I 3800 BarrettDrive I Raleigh, North Carolina 27609 NORTH CAROLINA ^ 919.791.4200 0�,mo E,Amnm Wl U-IR, DocuSign Envelope ID: EF459FA9-340D-4FEC-B116-E0492F828D05 4. The right of way to the outfall was well maintained. No visible impacts were noted immediately downstream of the effluent pipe. 5. The following deficiencies were noted during the inspection: • Influent and effluent flow meters were last calibrated on February 2, 2022, permit requires flow meters to be calibrated at least annually. • ORC visitation has not been documented. Please respond in writing within 30 days of receipt of this letter regarding Item 5. If you have any questions regarding the attached reports or any of the findings, please contact Cheng Zhang at: (919) 791-4200 (or email: chen .zhan deq.nc.gov). Sincerely, DocuSigned by: Vaun t,SSa f. 62916E6AB32144F... Vanessa E. Manuel, Assistant Regional Supervisor Water Quality Regional Operations Section Raleigh Regional Office Division of Water Resources, NCDEQ Attachment(s): EPA Water Compliance Inspection Report Cc: Laserfiche D � �� North Carolina Department of Environmental Quality I Division of Water Resources 512 North Salisbury Street 1 1611 Mail Service Center I Raleigh, North Carolina 27699-1611 NORTH CAROLINA ��` 919.707.9000 nnpn .mo EnWromm�nfal nual DocuSign Envelope ID: EF459FA9-340D-4FEC-B116-E0492F828D05 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 NCO020559 I11 121 23/06/07 I17 18I � I 19 I s I 201 I 211IIIII 111111III II III III1 I I IIIII IIIIIIIII II r6 Inspection Work Days Facility Self -Monitoring Evaluation Rating B1 QA ---------------------- Reserved ------------------- 67 I 72 I ni I 71 I 74 79 I I I I I I I80 701 I 71 I LL -1 I I LJ 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 Dermit Number) 09:30AM 23/06/07 19/08/01 Henderson Water Reclamation Facility 1646 W Andrews Ave Exit Time/Date Permit Expiration Date Henderson NC 275362555 12:30PM 23/06/07 23/03/31 Name(s) of Onsite Representative(s)/Titles(s)/Phone and Fax Number(s) Other Facility Data Clarissa LipscombH CPO KLRWS ORC/252-438-2141 /2524387866 Clarissa M Lipscomb/ORC/252-438-2142/ Name, Address of Responsible Official/Title/Phone and Fax Number Contacted Terrell Blackmon,PO Box 1434 Henderson NC 275361434/City Manager/252-430-5701 / 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 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: DocuSigned by: 7/5/2023 Cheng Zhan DWR/RRO WQ/919-791-4200/ Kevin Fowler off" "��w DWR/RRO WQ/919-791-4200/ 7/5/2023 D6171508E1EC41 F04A5B95DCE14CC_. Signature of Management Q A Reviewer Agency/Office/Phone and Fax Numbers Date DocuSigned by: 7/5/2023 VaAn t,SSa \I— 2916 S%W62) EPA POrm 144E ev 9-94 Previous editions are obsolete. Page# DocuSign Envelope ID: EF459FA9-340D-4FEC-B116-E0492F828D05 NPDES yr/mo/day Inspection Type (Cont.) NCO020559 I11 12I 23/06/07 117 18 i c i Section D: Summary of Finding/Comments (Attach additional sheets of narrative and checklists as necessary) The current permit expired on March 31, 2023. Renewal application was received by the Division on November 28, 2022. The 4.14 MGD facility consists of the following units: influent pump station; dual bar screens; grit removal system; biological nutrient removal system — 4 anaerobic basins, 2 anoxic zones, 2 oxidation ditches with 4 aerators ( 100 HP); two secondary clarifiers; UV disinfection with sodium hypochlorite backup; four (4) tertiary sand filters; post aeration; aerobic digester; sludge holding tank; waste activated sludge pumps, screw thickener; and screw thickener discharge pump. At the time of inspection, the following treatment units were not in used due to low flow: one of two BNR ditches, and two of four tertiary filters. Color of the influent in the oxidation ditch appeared chocolate brown. Foam covered about 50% of the basin. Effluent flowing at the weirs of the secondary clarifier and clear well of the tertiary sand filters appeared clear. Sludge blankets in the secondary clarifiers were less than a foot. The screw thickener was in operation at the time of inspection. The aerobic digester was about 3/4 full. Discharge Monitoring Report records for for July 2022 and January 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 was checked in a cursory manner. All calibrations of instruments and temperatures of refrigerators and other equipment are recorded daily in a log book. The following deficiencies were noted during the inspection: 1. Influent and effluent flow meters were last calibrated on February 2, 2022, permit requires flow meters to be calibrated at least annually; 2. ORC visitation has not been documented. Page# DocuSign Envelope ID: EF459FA9-340D-4FEC-B116-E0492F828D05 Permit: NCO020559 Inspection Date: 06/07/2023 Owner -Facility: Henderson Water Reclamation Facility Inspection Type: Compliance Evaluation 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 ❑ ❑ ❑ Solids, pH, DO, Sludge Judge, and other that are applicable? Comment: Facility analyze MLSS, DO, temperature, PH, settleable solids, sludge blanket for process control 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? 0 ❑ ❑ ❑ Is access to the plant site restricted to the general public? 0 ❑ ❑ ❑ Is the inspector granted access to all areas for inspection? ■ ❑ ❑ ❑ Comment: Influent pump station needs to be added to the treatment components list 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? ■ ❑ ❑ ❑ Are all pumps present? 0 ❑ ❑ ❑ Are all pumps operable? 0 ❑ ❑ ❑ Are float controls operable? 0 ❑ ❑ ❑ Is SCADA telemetry available and operational? 0 ❑ ❑ ❑ Is audible and visual alarm available and operational? ❑ ❑ 0 ❑ Comment: Four pumps 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? 0 ❑ ❑ ❑ Is disposal of screening in compliance? 0 ❑ ❑ ❑ Is the unit in good condition? 0 ❑ ❑ ❑ Comment: Two bar screens Page# 3 DocuSign Envelope ID: EF459FA9-340D-4FEC-B116-E0492F828D05 Permit: NCO020559 Inspection Date: 06/07/2023 Bar Screens Owner -Facility: Henderson Water Reclamation Facility Inspection Type: Compliance Evaluation Grit Removal 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? Comment: One channel with grit pump in use, a spare channel for future expansion Oxidation Ditches Are the aerators operational? Are the aerators free of excessive solids build up? # 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? Are settleometer results acceptable (> 30 minutes)? Is the DO level acceptable?(1.0 to 3.0 mg/1) Are settelometer results acceptable?(400 to 800 ml/I in 30 minutes) Yes No NA NE Yes No NA NE • ❑ ❑ ❑ • ❑ ❑ ❑ • ❑ ❑ ❑ Yes No NA NE • ❑ ❑ ❑ • ❑ ❑ ❑ • ❑ ❑ ❑ ❑ ■ ❑ ❑ • ❑ ❑ ❑ • ❑ ❑ ❑ • ❑ ❑ ❑ • ❑ ❑ ❑ Comment: One of the two oxidation ditches were online at the time of inspection. Anaerobic zone (influent goes into) and anoxic zone (influent and returned mixed liquor go into) at the head of each oxidation ditch, for biological nutrient removal. Foam covered more than 50% of the basin's surface. Operator explained that it was common in late spring/early summer, and was trying to reduce the amount of foam by wasting more. MLSS was about 2500 mg/L. 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? 0 ❑ ❑ ❑ Are weirs level? 0 ❑ ❑ ❑ Is the site free of weir blockage? ■ ❑ ❑ ❑ Is the site free of evidence of short-circuiting? ■ ❑ ❑ ❑ Is scum removal adequate? 0 ❑ ❑ ❑ Is the site free of excessive floating sludge? 0 ❑ ❑ ❑ Is the drive unit operational? 0 ❑ ❑ ❑ Page# 4 DocuSign Envelope ID: EF459FA9-340D-4FEC-B116-E0492F828D05 Permit: NCO020559 Inspection Date: 06/07/2023 Owner -Facility: Henderson Water Reclamation Facility Inspection Type: Compliance Evaluation Secondary Clarifier 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: Sludge blankets were 0.25 and 0.75 foot on the day of inspection. Filtration (High Rate Tertiary) Type of operation: 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? Yes No NA NE ❑ ❑ ❑ ❑ ❑ ❑ ❑ ❑ ❑ Yes No NA NE Down flow ■ ❑ ❑ ❑ ■ ❑ ❑ ❑ ■ ❑ ❑ ❑ ❑ ❑ ❑ ❑ ❑ ❑ ❑ ❑ ❑ Comment: Two of four filters were online due to low flow. Filters are backwashed once per da 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: Two banks of UV in series, each with three modules. The UV units were being serviced by a contractor at the time of insDection Disinfection -Liquid Yes No NA NE Is there adequate reserve supply of disinfectant? ❑ ❑ ■ ❑ (Sodium Hypochlorite) Is pump feed system operational? ❑ ❑ ■ ❑ Is bulk storage tank containment area adequate? (free of leaks/open drains) ❑ ❑ 0 ❑ 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? ❑ ❑ 0 ❑ Comment: Backup system has not been used in the past years. Page# 5 DocuSign Envelope ID: EF459FA9-340D-4FEC-B116-E0492F828D05 Permit: NC0020559 Owner -Facility: Inspection Date: 06/07/2023 Inspection Type: Henderson Water Reclamation Facility Compliance Evaluation De -chlorination Yes No NA NE Type of system ? Liquid Is the feed ratio proportional to chlorine amount (1 to 1)? ❑ ❑ ❑ Is storage appropriate for cylinders? ❑ ❑ 0 ❑ # Is de -chlorination substance stored away from chlorine containers? ❑ ❑ 0 ❑ Are the tablets the proper size and type? ❑ ❑ 0 ❑ Comment: Backup system has not been used in the past years. Are tablet de -chlorinators operational? ❑ ❑ ❑ Number of tubes in use? Comment: Aerobic Digester Yes No NA NE Is the capacity adequate? 0 ❑ ❑ ❑ Is the mixing adequate? 0 ❑ ❑ ❑ Is the site free of excessive foaming in the tank? ■ ❑ ❑ ❑ # Is the odor acceptable? 0 ❑ ❑ ❑ # Is tankage available for properly waste sludge? 0 ❑ ❑ ❑ Comment: The digester was about 3/4 full at the time of inspection. The one million gallon sludge holding tank has not been used in the past year. Pumps-RAS-WAS Yes No NA NE Are pumps in place? 0 ❑ ❑ ❑ Are pumps operational? 0 ❑ ❑ ❑ Are there adequate spare parts and supplies on site? ■ ❑ ❑ ❑ Comment: Three RAS-WAS pumps 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 • ❑ ❑ ❑ • ❑ ❑ ❑ • ❑ ❑ ❑ ■ ❑ ❑ ❑ ■ ❑ ❑ ❑ • ❑ ❑ ❑ • ❑ ❑ ❑ Page# 6 DocuSign Envelope ID: EF459FA9-340D-4FEC-B116-E0492F828D05 Permit: NCO020559 Inspection Date: 06/07/2023 Solids Handling Equipment Owner -Facility: Henderson Water Reclamation Facility Inspection Type: Compliance Evaluation Comment: Screw thickener was in operation at the time of inspection Effluent Pipe 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: Chemical Feed Is containment adequate? Is storage adequate? Are backup pumps available? Is the site free of excessive leaking? Yes No NA NE Yes No NA NE • ❑ ❑ ❑ • ❑ ❑ ❑ ❑ ❑ ■ ❑ Yes No NA NE ❑ ❑ ■ ❑ ❑ ❑ ■ ❑ ❑ ❑ ■ ❑ ❑ ❑ ■ ❑ Comment: Facility does not feed chemicals to sustain treatment processes (except that polymers are fed to wasted sludge before being dewatered by the screw thickener 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: The generator is tested twice per month Laboratory 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? Yes No NA NE ■ ❑ ❑ ❑ • ❑ ❑ ❑ • ❑ ❑ ❑ • ❑ ❑ ❑ • ❑ ❑ ❑ • ❑ ❑ ❑ ■ ❑ ❑ ❑ Yes No NA NE • ❑ ❑ ❑ • ❑ ❑ ❑ • ❑ ❑ ❑ • ❑ ❑ ❑ ■ ❑ ❑ ❑ Page# 7 DocuSign Envelope ID: EF459FA9-340D-4FEC-B116-E0492F828D05 Permit: NCO020559 Owner -Facility: Henderson Water Reclamation Facility Inspection Date: 06/07/2023 Inspection Type: Compliance Evaluation Laboratory Yes No NA NE Incubator (BOD) set to 20.0 degrees Celsius +/- 1.0 degrees? 0 ❑ ❑ ❑ Comment: Influent Sampling Yes No NA NE # Is composite sampling flow proportional? 0 ❑ ❑ ❑ Is sample collected above side streams? 0 ❑ ❑ ❑ Is proper volume collected? ■ ❑ ❑ ❑ Is the tubing clean? 0 ❑ ❑ ❑ # Is proper temperature set for sample storage (kept at less than or equal to 6.0 0 ❑ ❑ ❑ degrees Celsius)? Is sampling performed according to the permit? 0 ❑ ❑ ❑ Comment: Effluent Sampling Yes No NA NE Is composite sampling flow proportional? 0 ❑ ❑ ❑ Is sample collected below all treatment units? 0 ❑ ❑ ❑ Is proper volume collected? ■ ❑ ❑ ❑ Is the tubing clean? 0 ❑ ❑ ❑ # 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: Upstream / Downstream Sampling Yes No NA NE Is the facility sampling performed as required by the permit (frequency, sampling type, 0 ❑ ❑ ❑ and sampling location)? Comment: Nutrient Removal Yes No NA NE # Is total nitrogen removal required? M ❑ ❑ ❑ # Is total phosphorous removal required? 0 ❑ ❑ ❑ Type Biological # Is chemical feed required to sustain process? ❑ 0 ❑ ❑ Is nutrient removal process operating properly? M ❑ ❑ ❑ Page# 8 DocuSign Envelope ID: EF459FA9-340D-4FEC-B116-E0492F828D05 Permit: NCO020559 Owner -Facility: Henderson Water Reclamation Facility Inspection Date: 06/07/2023 Inspection Type: Compliance Evaluation Nutrient Removal Yes No NA NE Comment: Chemical feed is not needed to sustain process 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? ❑ ❑ ■ ❑ Comment: Flow meter was last calibrated on 2/2/2022 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: Flow meter was last calibrated on 2/2/2022 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? ❑ ■ ❑ ❑ Page# 9 DocuSign Envelope ID: EF459FA9-340D-4FEC-B116-E0492F828D05 Permit: NCO020559 Inspection Date: 06/07/2023 Owner -Facility: Henderson Water Reclamation Facility Inspection Type: Compliance Evaluation Record Keeping 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? Comment: ORC and backup ORC need to keep a visitation log Yes No NA NE ■ ❑ ❑ ❑ ■ ❑ ❑ ❑ ■ ❑ ❑ ❑ ■ ❑ ❑ ❑ Page# 10