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Home My WebLink AboutWQ0031317_Compliance Evaluation Inspection_20231128DocuSign Envelope ID: E09FACOF-8953-4214-85B6-894C2E8CO609 ROY COOPER Governor ELIZABETH S. BISER Secretary RICHARD E. ROGERS, JR. Director David Anderson Global Nuclear Fuel - Americas LLC PO Box 780 Wilmington, NC 28402-0780 NORTH CAROLINA Environmental Quality November 28, 2023 SUBJECT: Compliance Inspection Report GNF-A Wilmington - Castle Hayne WWTP Non -discharge Permit No. WQ0031317 New Hanover County Dear Permittee: The North Carolina Division of Water Resources conducted an inspection of the GNF-A Wilmington - Castle Hayne WWTP on 11/16/2023. This inspection was conducted to verify that the facility is operating in compliance with the conditions and limitations specified in Non -discharge Permit No. WQ0031317. 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. If you should have any questions, please do not hesitate to contact Geoff Kegley with the Water Quality Regional Operations Section in the Wilmington Regional Office at 910-796-7215 or via email at geoff.kegley@deq.nc.gov. Sincerely, DocuSigned by: To.•,. '�.,rrin5�on for CDAFCKC8FCD446... Morelia Sanchez -King, Regional Supervisor Water Quality Regional Operations Section Wilmington Regional Office Division of Water Resources, NCDEQ ATTACHMENTS Cc: Karen Williams, EHS Programs Manager, GNF-A DWR Laserfiche files D North Carolina Department of Environmental quality I Division of Water Resources ,./ Wiimington Regional Office 1127 Cardinal Drive Extension I Wilmington. North Carolina 26405 910.796,7215 DocuSign Envelope ID: E09FACOF-8953-4214-85B6-894C2E8C0609 Compliance Inspection Report Permit: WQ0031317 Effective: 03/01/23 Expiration: 09/30/29 Owner: Global Nuclear Fuel - Americas LLC SOC: Effective: Expiration: Facility: GNF-A Wilmington -Castle Hayne WWTP County: New Hanover 3901 Castle Hayne Rd Region: Wilmington NC Hwy 133 Wilmington NC 28402 Contact Person: David Anderson Title: Facilities Manager Phone: 843-735-9086 Directions to Facility: Take US-117N/N College Rd to 1-40W, Continue on 1-40. Take exit 17 from 1-1 40W/US-1 7S, turn R onto NC-133N/Castle Hayne Road System Classifications: WW2, Primary ORC: Michael Wayne Phipps Certification: 986536 Phone: 910-617-9373 Secondary ORC(s): On -Site Representative(s): Related Permits: NC0001228 Global Nuclear Fuel - Americas LLC - GNF-A Wilmington - Castle Hayne WWTP Inspection Date: 11/16/2023 Entry Time 09:OOAM Exit Time: 12:30PM Primary Inspector: Geoff Kegley °`°S'gnee�d by: Phone: Secondary Inspector(s): EC017E2515MB41T-ED.Signed by: Bryan Lievre . "ac Kate Shadwell BAF550231BDD428.. Reason for Inspection: Routine Inspection Type: Compliance Evaluation Permit Inspection Type: Reclaimed Water Facility Status: 0 Compliant ❑ Not Compliant Question Areas: Treatment Flow Measurement -Effluent Treatment Flow Measurement -Water Use Records Treatment Filters Treatment Sludge Storage/Treatment Treatment Return pumps (See attachment summary) Treatment Flow Measurement -Influent Miscellaneous Questions Treatment Treatment Barscreen Record Keeping Treatment Disinfection End Use -Reuse Treatment Activated Sludge Treatment Flow Measurement Standby Power Page 1 of 7 DocuSign Envelope ID: E09FACOF-8953-4214-85B6-894C2E8CO609 Permit: WQ0031317 Owner - Facility: Global Nuclear Fuel - Americas LLC Inspection Date: 11/16/2023 Inspection Type : Compliance Evaluation Reason for Visit: Routine Inspection Summary: A routine compliance inspection of the Global Nuclear Fuel -Americas (GNF-A) WWTF was conducted on November 16, 2023. The purpose of the evaluation was to verify that the facility is operating in compliance with the conditions and limitations specified in Non -Discharge Permit W00031317. Karen Williams, EHS Programs Manager and Chris Cronin, EHS Environmental Specialist and operating staff were present during the inspection, along with Bryan Lievre from the Wilmington Regional Office and Kate Shadwell from the DWR Central Office. This facility treats the domestic wastewater from the industrial site through a Membrane Bioreactor (MBR) system to reclaim standards for the conjunctive use of site cooling towers. The effluent can be discharged to Outfall 002 of NPDES Permit NC0001228 if the demand for conjunctive reclaim use decreases or reclaim standards are not met. This outfall discharges to the Northeast Cape Fear River. The facility is a 75,000 gallon GPD reclaimed water generation, distribution, conjunctive utilization facility consisting of: • mechanical screw screen; rotary fine screen with 2 mm spacings • 19,400 gallon EQ tank #1 • 100,000 EQ tank #2 • 5,302 gallon anoxic tank • 5,494 gallon anoxic tank • 4 aeration basins with a total volume of 21,926 gallons • 6 sludge holding tanks with total capacity of 32,470 gallons • Two Zenon Membrane Bioreactor (MBR) units consisting of two cassettes with 8 filtration modules per cassette, Dual permeate pumps, dual backwash pumps, dual air scour blowers, and citric acid and chlorine cleaning system • Two ultraviolet (UV) disinfection units with 12 lamps each • 20,000 gallon reclaimed water storage tank and liquid chlorine injection to provide chlorine residual • dual reclaimed utilization pumps; 3,500 linear feet (LF) of 3-inch PVC piping to provide reclaimed water to the existing 200,000 GPD reverse osmosis water treatment facility for industrial process use, and to the cooling towers Currently, the plant is treating an average of approximately 12,000-14,000 gpd. A review of files since last inspection in March 2022 indicates that no monitoring exceedances have occurred. The GNF-A facility is compliant with the Non -Discharge Permit W00031317. Please review the comment sections of the inspection report for more details. Page 2 of 7 DocuSign Envelope ID: E09FACOF-8953-4214-85B6-894C2E8C0609 Permit: WQ0031317 Inspection Date: 11/16/2023 Owner - Facility: Global Nuclear Fuel - Americas LLC Inspection Type : Compliance Evaluation Reason for Visit: Routine Type Yes No NA NE Reuse (Quality) ❑ Infiltration System ❑ Lagoon Spray, LR ❑ Single Family Spray, LR ❑ Activated Sludge Spray, LR ❑ Activated Sludge Spray, HR ❑ Activated Sludge Drip, LR ❑ Single Family Drip ❑ Recycle/Reuse Treatment Yes No NA NE Are Treatment facilities consistent with those outlined in the current permit? 0 ❑ ❑ ❑ Do all treatment units appear to be operational? (if no, note below.) 0 ❑ ❑ ❑ Comment: Treatment Flow Measurement -Influent Yes No NA NE Is flowmeter calibrated annually? ❑ ❑ 0 ❑ Is flowmeter operating properly? ❑ ❑ ❑ Does flowmeter monitor continuously? ❑ ❑ ❑ Does flowmeter record flow? ❑ ❑ ❑ Does flowmeter appear to monitor accurately? ❑ ❑ ❑ Comment: Treatment Flow Measurement -Water Use Records Yes No NA NE Is water use metered? ❑ ❑ ❑ Are the daily average values properly calculated? ❑ ❑ 0 ❑ Comment: Treatment Flow Measurement -Effluent Yes No NA NE Is flowmeter calibrated annually? ❑ ❑ ❑ Is flowmeter operating properly? ❑ ❑ ❑ Does flowmeter monitor continuously? ❑ ❑ ❑ Does flowmeter record flow? ❑ ❑ ❑ Does flowmeter appear to monitor accurately? 0 ❑ ❑ ❑ Comment: The effluent flowmeter was calibrated on 6/1 /2023. Standby Power Yes No NA NE Is automatically activated standby power available? 0 ❑ ❑ ❑ Page 3 of 7 DocuSign Envelope ID: E09FACOF-8953-4214-85B6-894C2E8CO609 Permit: WQ0031317 Owner - Facility: Global Nuclear Fuel - Americas LLC Inspection Date: 11/16/2023 Inspection Type : Compliance Evaluation Reason for Visit: Routine Is generator tested weekly by interrupting primary power source? Is generator operable? Does generator have adequate fuel? Comment: The facility has access to dual power sources, the Sutton Plant and the Castle Hayne feed and power can be switched when one fails. A hook-up for a portable generator and a transfer switch is also available if needed. Portable generators are available on -site and additional generators are rented prior to predicted hurricane/storm events. Treatment Barscreen Yes No NA NE Is it free of excessive debris? 0 ❑ ❑ ❑ Is disposal of screenings in compliance? 0 ❑ ❑ ❑ Are the bars spaced properly? ❑ ❑ 0 ❑ Is the unit in good condition? 0 ❑ ❑ ❑ Comment: Treatment Activated Sludge Yes No NA NE Is the aeration mechanism operable? 0 ❑ ❑ ❑ Is the aeration basin thoroughly mixed? 0 ❑ ❑ ❑ Is the aeration equipment easily accessed? ❑ ❑ ❑ Is Dissolved Oxygen adequate? ❑ ❑ ❑ Are Settleometer results acceptable? ❑ ❑ ❑ Is activated sludge an acceptable color? 0 ❑ ❑ ❑ Comment: Each aeration basin has DO monitoring probes connected to a PLC. Mix liquor is typically 9,800-10,200 mg/I. A high water alarm was simulated and was functioning properly, with the ORC receiving a phone call alert. Treatment Return pumps Yes No NA NE Are they in place? 0 ❑ ❑ ❑ Are they operational? 0 ❑ ❑ ❑ Comment: Treatment Filters Yes No NA NE Is the filter media present? 0 ❑ ❑ ❑ Is the filter media the correct size and type? 0 ❑ ❑ ❑ Is the air scour operational? 0 ❑ ❑ ❑ Is the scouring acceptable? 0 ❑ ❑ ❑ Is the clear well free of excessive solids? ❑ ❑ 0 ❑ Is the mud well free of excessive solids and filter media? ❑ ❑ 0 ❑ Does backwashing frequency appear adequate? 0 ❑ ❑ ❑ Comment: The membrane units alternate after a set amount of filter/back pulse cycles. The MBR units are cleaned annually with a chlorine and citric acid cleaning system. Page 4 of 7 DocuSign Envelope ID: E09FACOF-8953-4214-85B6-894C2E8CO609 Permit: WQ0031317 Owner - Facility: Global Nuclear Fuel - Americas LLC Inspection Date: 11/16/2023 Inspection Type : Compliance Evaluation Reason for Visit: Routine Treatment Sludge Storage/Treatment Yes No NA NE Is the aeration operational? 0 ❑ ❑ ❑ Is the aeration pattern even? 0 ❑ ❑ ❑ If required, are Sanitary "Ts" present in tankage? ❑ ❑ ❑ ❑ Comment: Solids from the digesters are treated with lime before and after it is processed through a filter press. Solids are then bagged in super -sacks and sent to Energy Solutions, LLC (Bulk Waste Facility) in Clive, Utah. Manifest paperwork was readily available. Treatment Disinfection Yes No NA NE Is the system working? 0 ❑ ❑ ❑ Do the fecal coliform results indicate proper disinfection? 0 ❑ ❑ ❑ Is there adequate detention time (-30 minutes)? ❑ ❑ 0 ❑ Is the system properly maintained? 0 ❑ ❑ ❑ If gas, does the cylinder storage appear safe? ❑ ❑ 0 ❑ Is the fan in the chlorine feed room and storage area operable? ❑ ❑ 0 ❑ Is the chlorinator accessible? 0 ❑ ❑ ❑ If tablets, are tablets present? ❑ ❑ 0 ❑ Are the tablets the proper size and type? ❑ ❑ 0 ❑ Is contact chamber free of sludge, solids, and growth? ❑ ❑ 0 ❑ If UV, are extra UV bulbs available? 0 ❑ ❑ ❑ If UV, is the UV intensity adequate? ❑ ❑ ❑ # Is it a dual feed system? 0 ❑ ❑ ❑ Does the Stationary Source have more than 2500 Ibs of Chlorine (CAS No. 7782-50-5)? ❑ ❑ 0 ❑ If yes, then is there a Risk Management Plan on site? ❑ ❑ 0 ❑ If yes, then what is the EPA twelve digit ID Number? (1000- If yes, then when was the RMP last updated? Comment: UV disinfection is utilized and effluent is stored in a 20,000 gallon tank with a liquid chlorine infection pump to provide chlorine residual in the reclaimed utilization system. When effluent is sent to Outfall 002, the valve is located before the chlorine injection and therefore bypassed. The UV bulbs and liners are changed out every year and a set of 4 replacement bulbs are kept on hand. Record Keeping Is a copy of current permit available? Are monitoring reports present: NDMR? NDAR? Are flow rates less than of permitted flow? Are flow rates less than of permitted flow? Are application rates adhered to? Is GW monitoring being conducted, if required (GW-59s submitted)? / ]r- ]..�.1N • ❑ ❑ ❑ • ❑ ❑ ❑ • ❑ ❑ ❑ • ❑ ❑ ❑ • ❑ ❑ ❑ ❑❑■❑ ❑❑■❑ Page 5 of 7 DocuSign Envelope ID: E09FACOF-8953-4214-85B6-894C2E8CO609 Permit: WQ0031317 Owner - Facility: Global Nuclear Fuel - Americas LLC Inspection Date: 11/16/2023 Inspection Type : Compliance Evaluation Reason for Visit: Routine Are all samples analyzed for all required parameters? 0 ❑ ❑ ❑ Are there any 2L GW quality violations? ❑ ❑ 0 ❑ Is GW-59A certification form completed for facility? ❑ ❑ 0 ❑ Is effluent sampled for same parameters as GW? ❑ ❑ 0 ❑ Do effluent concentrations exceed GW standards? ❑ ❑ 0 ❑ Are annual soil reports available? ❑ ❑ 0 ❑ # Are PAN records required? ❑ ❑ 0 ❑ # Did last soil report indicate a need for lime? ❑ ❑ 0 ❑ If so, has it been applied? ❑ ❑ 0 ❑ Are operational logs present? 0 ❑ ❑ ❑ Are lab sheets available for review? 0 ❑ ❑ ❑ Do lab sheets support data reported on NDMR? 0 ❑ ❑ ❑ Do lab sheets support data reported on GW-59s? ❑ ❑ 0 ❑ Are Operational and Maintenance records present? 0 ❑ ❑ ❑ Were Operational and Maintenance records complete? 0 ❑ ❑ ❑ Has permittee been free of public complaints in last 12 months? ❑ ❑ ❑ Is a copy of the SOC readily available? ❑ ❑ 0 ❑ No treatment units bypassed since last inspection? 0 ❑ ❑ ❑ Comment: A daily check list is used by staff to document operations of the plant and a work order system is used for maintenance. Calibrations records and bench sheets for field parameters were complete and organized. All other required parameters are analyzed by Envirochem. The turbidity meter is calibrated quarterly with the last one performed on 10/1/2023. Permit does not required composite sampling, grab samples are taken at a sampling port after the UV disinfection, before the reclaimed storage tank. End Use -Reuse Yes No NA NE Is the acreage in the permit being utilized? ❑ ❑ ❑ Does the acreage specified in the permit correspond to the measured acreage at the site? ❑ ❑ ❑ Are all essential units provided in duplicate? ❑ ❑ ❑ Is an automatically activated standby power source available? ❑ ❑ ❑ Is the equalization capacity adequate? ❑ ❑ ❑ Is aerated flow equalization present? ❑ ❑ ❑ Has the turbidity meter been calibrated in the last 12 months? ❑ ❑ ❑ Does the turbidity meter have recording capabilities? ❑ ❑ ❑ Is all flow diverted at the appropriate times? ❑ ❑ ❑ Is all upset wastewater diverted from reuse storage unit? ❑ ❑ ❑ Is all upset wastewater treated, retreated, or disposed of acceptably? ❑ ❑ ❑ Is upset wastewater treated prior to discharge to irrigation storage? ❑ ❑ ❑ Is public access restricted from irrigation area during active site use? ❑ ❑ ❑ Page 6 of 7 DocuSign Envelope ID: E09FACOF-8953-4214-85B6-894C2E8CO609 Permit: WQ0031317 Owner - Facility: Global Nuclear Fuel - Americas LLC Inspection Date: 11/16/2023 Inspection Type : Compliance Evaluation Reason for Visit: Routine If golf course, is a sign posted in plain sight on the club house? ❑ ❑ 0 ❑ Is the cover crop acceptable? ❑ ❑ 0 ❑ Are buffers adequate? ❑ ❑ 0 ❑ Is the site free of ponding/runoff? ❑ ❑ 0 ❑ Is the acreage in the permit being utilized? ❑ ❑ 0 ❑ Is the application equipment acceptable? ❑ ❑ 0 ❑ Is the application area free of limiting slopes? ❑ ❑ 0 ❑ How close is the closest water supply well? ❑ ❑ ❑ Are any supply wells within the CB? ❑ ❑ 0 ❑ Are any supply wells within 250' of the CB? ❑ ❑ 0 ❑ Is municipal water available in the area? 0 ❑ ❑ ❑ Are GW monitoring wells required? ❑ ❑ 0 ❑ Are GW monitoring wells located properly w/ respect to RB and CB? ❑ ❑ 0 ❑ Are GW monitoring wells properly constructed, including screened interval? ❑ ❑ 0 ❑ Comment: Reclaimed effluent is stored in the 20,000 gallon tank and used for facility cooling towers. All reclaimed water piping and appurtenances are labeled and color -coded purple as required. Entire facility is fenced/gated and access is restricted. Page 7 of 7