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Home My WebLink AboutNC0024538_Compliance Evaluation Inspection_20231215ROY COOPER Governor ELIZABETH S. BISER Secretary RICHARD E. ROGERS, JR. Director Brian Wilson, Director of Water Resources City of Shelby Post Office Box 207 Shelby, NC 28151 SUBJECT: Compliance Evaluation Inspection City of Shelby/First Broad River WWTP NPDES Permit No. NCO024538 Cleveland County Dear Mr. Wilson: NORTH CAROLINA Environmental Quality December 15, 2023 Enclosed is a copy of the Compliance Evaluation Inspection (CEI) Report for the inspection conducted at the subject facility on December 7, 2023, by Mr. Wes Bell of this Office. This Office would like to thank all WWTP staff for their cooperation and assistance that was provided throughout this inspection. Please advise the facility's Operator -in -Responsible Charge (ORC) of our findings by forwarding the enclosed report. Should you have any questions concerning this report, please do not hesitate to contact Mr. Bell at (704) 235-2192 or at wes.bell(kdeq.nc. gov. Enclosure: Inspection Report Cc: NPDES Program Files - Laserfiche Sincerely, DocuSigned by: A wNNuft F161 F669A2D84A3... Andrew H. Pitner, P.G., Regional Supervisor Water Quality Regional Operations Section Mooresville Regional Office Division of Water Resources, NCDEQ 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 704.6631699 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 NCO024538 111 121 23/12/07 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 2.0 701d I 71 I„ 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 Dermit Number) 09:15AM 23/12/07 20/03/01 First Broad River WWTP 1940 S Lafayette St Exit Time/Date Permit Expiration Date Shelby NC 28152 01:50PM 23/12/07 24/08/31 Name(s) of Onsite Representative(s)/Titles(s)/Phone and Fax Number(s) Other Facility Data Steven C Smith/ORC/704-484-6850/ Name, Address of Responsible Official/Title/Phone and Fax Number Contacted Rick Howell,PO Box 207 Shelby NC 281510207/City Manager/704-484-6866/7044846871 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 ocuSigned by: Wes Bell DWR/MRO WQ/704-235-2192/ 12/15/2023 2 r6& E�D:,,, 96D90=437... Signature of Man nV9 rA4;taviewer Agency/Office/Phone and Fax Numbers Date Andrew Pitn r A*-. ` H P"*ftR/MRO WQ/704-663-1699 Ext.2180/ 12/15/2023 F161FB69A2D84A3... EPA Form 3560-3 (Rev 9-94) Previous editions are obsolete. Page# NPDES yr/mo/day Inspection Type NC0024538 I11 12I 23/12/07 117 18 i c i Section D: Summary of Finding/Comments (Attach additional sheets of narrative and checklists as necessary) On -site Representatives: The following City staff were in attendance during the inspection: Mr. Brad Greene, Mr. Steven Smith and Mr. John Reuscher. Page# Permit: NCO024538 Owner -Facility: First Broad River WWTP Inspection Date: 12/07/2023 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 ❑ ❑ ■ ❑ 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: The City implements a Division -approved Industrial Pretreatment Program. The last compliance evaluation inspection at this facility was performed by DWR staff on 9/14/2022. 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? ■ ❑ ❑ ❑ 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? ■ ❑ ❑ ❑ Page# 3 Permit: NCO024538 Inspection Date: 12/07/2023 Owner -Facility: First Broad River WWTP Inspection Type: Compliance Evaluation Record Keeping Yes No NA NE Comment: The records reviewed durinq the inspection were organized and well maintained. Discharge Monitoring Reports (eDMRs) were reviewed for the period November 2022 through October 2023. No limit and/or monitoring violations were reported. The December 2022 eDMR will be revised to remove an effluent cyanide result (composite sample) reported on 12/30/22 that was performed as part of an investigation regarding sample contamination. Note: The investigation was discussed in the Comments Section. 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? 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? ❑ ❑ ❑ ■ Comment: Influent and effluent analyses (includinq field) are performed under the City's municipal laboratory certification #238. Pace Analytical Services and Meritech, Inc. (toxicity) have been contracted to provide analytical support. The facility staff must ensure that the 4.0 , 7.0 and 10.0 SU buffers used for the calibration of the effluent pH meter (field) are included in the overall calibration documentation that currently only includes the 7.0 SU check standard verification. Influent Sampling # 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? Comment: The subject permit requires influent BOD and TSS composite samples. Effluent Sampling Is composite sampling flow proportional? Is sample collected below all treatment units? Is proper volume collected? Is the tubing clean? Yes No NA NE • ❑ ❑ ❑ • ❑ ❑ ❑ • ❑ ❑ ❑ • ❑ ❑ ❑ • ❑ ❑ ❑ ■ ❑ ❑ ❑ Yes No NA NE • ❑ ❑ ❑ • ❑ ❑ ❑ • ❑ ❑ ❑ • ❑ ❑ ❑ Page# 4 Permit: NCO024538 Inspection Date: 12/07/2023 Owner -Facility: First Broad River WWTP Inspection Type: Compliance Evaluation Effluent Sampling # 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: The subject permit requires composite and grab effluent samples. Upstream / Downstream Sampling Is the facility sampling performed as required by the permit (frequency, sampling type, and sampling location)? Comment: Operations & Maintenance 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: The wastewater treatment facility appeared to be properly operated and well Yes No NA NE ■ ❑ ❑ ❑ ■ ❑ ❑ ❑ Yes No NA NE ■ ❑ ❑ ❑ Yes No NA NE ❑ ❑ ❑ ❑ ❑ ❑ maintained. The facility staff incorporate a comprehensive process control program with all measurements being documented and maintained on -site. In-depth operation and maintenance records are also maintained on -site. The facility is equipped with a SCADA system to assist the wastewater staff in treatment operations. The operations staff also have access to a phone that is connected to the telemetry type alarm system. Bar Screens Yes No NA NE Type of bar screen a.Manual ❑ b.Mechanical Are the bars adequately screening debris? 0 ❑ ❑ ❑ Is the screen free of excessive debris? ■ ❑ ❑ ❑ Is disposal of screening in compliance? 0 ❑ ❑ ❑ Is the unit in good condition? 0 ❑ ❑ ❑ Comment: Grit Removal Yes No NA NE Type of grit removal a.Manual ❑ b.Mechanical Is the grit free of excessive organic matter? 0 ❑ ❑ ❑ Page# 5 Permit: NC0024538 Owner -Facility: First Broad River WWTP Inspection Date: 12/07/2023 Inspection Type: Compliance Evaluation Grit Removal Yes No NA NE Is the grit free of excessive odor? 0 ❑ ❑ ❑ # Is disposal of grit in compliance? ❑ ❑ ❑ Comment: Screenings and grit are disposed at the County Landfill. 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? 0 ❑ ❑ ❑ 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: Primary Clarifier Yes No NA NE Is the clarifier free of black and odorous wastewater? 0 ❑ ❑ ❑ 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? 0 ❑ ❑ ❑ Is scum removal adequate? 0 ❑ ❑ ❑ Is the site free of excessive floating sludge? ■ ❑ ❑ ❑ Is the drive unit operational? 0 ❑ ❑ ❑ Is the sludge blanket level acceptable? 0 ❑ ❑ ❑ Is the sludge blanket level acceptable? (Approximately'/4 of the sidewall depth) 0 ❑ ❑ ❑ Comment: Both primaries are operational: however influent flows. Aeration Basins Mode of operation Type of aeration system Is the basin free of dead spots? Are surface aerators and mixers operational? one clarifier was in service due to low Yes No NA NE Ext. Air Diffused ■ ❑ ❑ ❑ ❑ ❑ ■ ❑ Page# 6 Permit: NCO024538 Owner -Facility: First Broad River WWTP Inspection Date: 12/07/2023 Inspection Type: Compliance Evaluation Aeration Basins Yes No NA NE Are the diffusers operational? 0 ❑ ❑ ❑ 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) M ❑ ❑ ❑ Comment: Two of the three aeration basin trains were in service. The mixed liquor appeared to be adequately mixed and oxygenated. Aqueous lime is added (as -needed) to maintain appropriate alkalinity/pH levels. 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) Yes No NA NE • ❑ ❑ ❑ • ❑ ❑ ❑ • ❑ ❑ ❑ • ❑ ❑ ❑ • ❑ ❑ ❑ • ❑ ❑ ❑ • ❑ ❑ ❑ • ❑ ❑ ❑ • ❑ ❑ ❑ • ❑ ❑ ❑ • ❑ ❑ ❑ Comment: All four secondary clarifiers were operational; however, only two clarifiers were in service. Pumps-RAS-WAS Are pumps in place? Are pumps operational? Are there adequate spare parts and supplies on site? Comment: Disinfection -Gas Are cylinders secured adequately? Are cylinders protected from direct sunlight? Is there adequate reserve supply of disinfectant? Yes No NA NE • ❑ ❑ ❑ • ❑ ❑ ❑ ❑ ❑ ❑ ■ Yes No NA NE • ❑ ❑ ❑ • ❑ ❑ ❑ • ❑ ❑ ❑ Page# 7 Permit: NCO024538 Inspection Date: 12/07/2023 Disinfection -Gas Owner -Facility: First Broad River WWTP Inspection Type: Compliance Evaluation 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 Ibs 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? Yes No NA NE ■ ❑ ❑ ❑ ■ ❑ ❑ ❑ ■ ❑ ❑ ❑ ❑ ❑ ❑ ■ ❑ ❑ ❑ ■ Comment: The chlorination and dechlorination systems are serviced annually by a contracted company (Piedmont Chlorinator). 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? ■ ❑ ❑ ❑ Are the tablets the proper size and type? ❑ ❑ ■ ❑ Comment: The ORC and staff must ensure that the sulfur dioxide is thoroughly mixed throughout the effluent channel prior to the effluent sampling location. Are tablet de -chlorinators operational? ❑ ❑ ■ ❑ Number of tubes in use? Comment: Flow Measurement - Effluent # 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? Yes No NA NE ■ ❑ ❑ ❑ ■ ❑ ❑ ❑ ■ ❑ ❑ ❑ ❑ ❑ ■ ❑ Comment: The effluent flow meter is calibrated annually and was last calibrated on 8/29/2023 b Fortech Automation Engineering. The ORC and staff must ensure that the contracted company performs an instantaneous check on the flow measurement system following calibration to verify the flow meter is reading less than 10% deviation from the true discharge rates. Effluent Pipe Is right of way to the outfall properly maintained? Yes No NA NE ■ ❑ ❑ ❑ Page# 8 Permit: NCO024538 Inspection Date: 12/07/2023 Effluent Pipe Owner -Facility: First Broad River WWTP Inspection Type: Compliance Evaluation Yes No NA NE 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? ❑ ❑ 0 ❑ Comment: The effluent appeared clear with trace suspended solids and no foam. The receiving stream did not appear to be negatively impacted. Anaerobic Digester Type of operation: Is the capacity adequate? # Is gas stored on site? Is the digester(s) free of tilting covers? Is the gas burner operational? Is the digester heated? Is the temperature maintained constantly? Is tankage available for properly waste sludge? Comment: The facility is equipped with two anaerobic digesters (both operational). 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 Fixed cover ■ ❑ ❑ ❑ ❑ ❑ ■ ❑ ❑ ❑ ■ ❑ ■ ❑ ❑ ❑ ■ ❑ ❑ ❑ ■ ❑ ❑ ❑ ■ ❑ ❑ ❑ Yes No NA NE ■ ❑ ❑ ❑ ■ ❑ ❑ ❑ ■ ❑ ❑ ❑ ❑ ❑ ❑ ■ ❑ ❑ ❑ ■ ■ ❑ ❑ ❑ ■ ❑ ❑ ❑ Comment: The facility is equipped with two belt presses, gravity thickener and filtrate storage tanks. The belt presses were not in service at the time of the inspection. Dewatered bio-solids are stored in a covered pad and ultimately land applied by EMA Resources under the authority of Permit No. WQ0042031. Standby Power Yes No NA NE Is automatically activated standby power available? 0 ❑ ❑ ❑ Is the generator tested by interrupting primary power source? 0 ❑ ❑ ❑ Is the generator tested under load? ■ ❑ ❑ ❑ Was generator tested & operational during the inspection? ❑ ❑ ❑ Page# 9 Permit: NC0024538 Owner -Facility: First Broad River WWTP Inspection Date: 12/07/2023 Inspection Type: Compliance Evaluation Standby Power Yes No NA NE Do the generator(s) have adequate capacity to operate the entire wastewater site? 0 ❑ ❑ ❑ Is there an emergency agreement with a fuel vendor for extended run on back-up ■ ❑ ❑ ❑ power? Is the generator fuel level monitored? ❑ ❑ ❑ Comment: The facility is equipped with two backup generators (1 — influent/headworks and 1 — main plant). Both -generators are checked quarterly and serviced annually by contracted companies. The generators are tested weekly and put under a load four times per year (at a minimum). In addition, the City participates in the Peak Shaving - Pro -gram. Page# 10