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Home My WebLink AboutNC0025909_Compliance Evaluation Inspection_20240202 SENT VIA ELECTRONIC MAIL ONLY: NO HARD COPY WILL BE MAILED. February 2, 2024 Doug Barrick Town of Rutherfordton Email: dbarrick@rutherfordton.net SUBJECT: Compliance Inspection Report Rutherfordton WWTP NPDES WW Permit No. NC0025909 Rutherford County Dear Permittee: The North Carolina Division of Water Resources conducted an inspection of the Rutherfordton WWTP on 1/23/2024. This inspection was conducted to verify that the facility is operating in compliance with the conditions and limitations specified in NPDES WW Permit No. NC0025909. 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 me at 828-296-4667 or via email at lauren.armeni@deq.nc.gov. Sincerely, Lauren Armeni, Environmental Specialist II Water Quality Regional Operations Section Asheville Regional Office Division of Water Resources, NCDEQ ATTACHMENTS: Inspection Report Ec: Laserfiche Phillip Reynolds (ORC, Veolia) Alex Cabrera (BORC, Veolia) DocuSign Envelope ID: 320836F1-3FE7-47D2-A98A-7F69A1E5B28E 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 NC0025909 24/01/23 C S31112171819 20 21 66 Inspection Work Days Facility Self-Monitoring Evaluation Rating B1 QA ----------------------Reserved------------------- 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) Rutherfordton WWTP NC Hwy 221 Rutherfordton NC 28139 Entry Time/Date Permit Effective Date Exit Time/Date Permit Expiration Date 10:00AM 24/01/23 22/12/01 Name(s) of Onsite Representative(s)/Titles(s)/Phone and Fax Number(s) /// Phillip E Reynolds/ORC/828-287-2141/ Other Facility Data 12:00PM 24/01/23 27/07/31 Name, Address of Responsible Official/Title/Phone and Fax Number Doug Barrick,129 N Main St Rutherfordton NC 28139/Town Manager/828-287-3520/Contacted Yes Section C: Areas Evaluated During Inspection (Check only those areas evaluated) Permit Flow Measurement Operations & Maintenance Records/Reports Self-Monitoring Program Sludge Handling Disposal Effluent/Receiving Waters 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 Lauren E Armeni DWR/ARO WQ/828-296-4500/ Mara G Chamlee DWR/ARO WQ/828-296-4500/ Rachel Rose DWR/ARO WQ/828-296-4500/ Signature of Management Q A Reviewer Agency/Office/Phone and Fax Numbers Date EPA Form 3560-3 (Rev 9-94) Previous editions are obsolete. Page#1 DocuSign Envelope ID: 320836F1-3FE7-47D2-A98A-7F69A1E5B28E 2/2/2024 2/2/2024 2/2/2024 2/2/2024 NPDES yr/mo/day 24/01/23 Inspection Type C3111218 1 Section D: Summary of Finding/Comments (Attach additional sheets of narrative and checklists as necessary) Lauren Armeni, Mara Chamlee, and Rachel Rose, with the Asheville Regional Office, conducted a Compliance Evaluation Inspection of the Rutherfordton WWTP on January 23, 2024. This inspection was conducted to determine whether the facility is being operated and maintained in compliance with NPDES Permit No. NC0025909. Phillip Reynolds (ORC, Veolia) and Alex Cabrera (BORC, Veolia) were present and assisted with the inspection. Overall, the facility was well-maintained and operated. There are several upgrades throughout the plant that are budgeted over the next few years and will be done in phases. These upgrades are mentioned throughout the report. The following items were noted during the inspection: 1. Permit: A Corrective Action Plan for nitrate limitations was submitted to the DEQ on January 31, 2024. The permit components list from the permit issued in 2022 lists a mechanical bar screen and grit removal. The facility currently does not have these two components, but should by the time the permit renews again; therefore, the components will be kept as is and changed if needed during the next renewal. Additionally, the current permit lists three aeration basins but there are only two. 2. Headworks (bar screen): As mentioned in the 2021 report, the screw auger is rated for 1.5 MGD and cannot handle wet weather flows well. The manual bar screen continues to be used when flows bypass the auger during heavy rain events. The grating is spaced too far apart and contributes to additional debris passing into the system. There is still no grit removal system; however, there are plans to upgrade the headworks by removing the screw auger and adding a mechanical bar screen/grit removal. 3. Aeration Basins/Secondary Clarifier: At the time of the inspection, settleability was 13% after 45 minutes. Mr. Reynolds indicated that they were having some issues with their biota and were in the process of troubleshooting the issues. The sludge blanket in secondary clarifier #2 did not reflect this (2' out of 12' water) because they have more control over their blanket due to the splitter box before the clarifiers. NC0025909 17 (Cont.) Page#2 DocuSign Envelope ID: 320836F1-3FE7-47D2-A98A-7F69A1E5B28E Permit:NC0025909 Inspection Date:01/23/2024 Owner - Facility: Inspection Type: Rutherfordton 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 permit has Special Condition A.(5.) - Schedule of Compliance for Nitrate Limitations. The permit components list did not accurately reflect the current components at the WWTP. See summary for details. 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? Process controls analyzed include pH, DO, sludge judge, MLSS, settleable solids, ammonia, nitrate, and SVIs. 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? Page#3 DocuSign Envelope ID: 320836F1-3FE7-47D2-A98A-7F69A1E5B28E Permit:NC0025909 Inspection Date:01/23/2024 Owner - Facility: Inspection Type: Rutherfordton WWTP Compliance Evaluation Record Keeping Yes No NA NE 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: 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? Influent sampling is time-based. At the time of the inspection, the outside of the tubing was dirty. It is recommended to replace this tubing. Mr. Reynolds indicated that the thermometers inside the sampler fridge are replaced annually. 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? Flow initially goes through a screw auger and then a manual bar screen. The screw auger is manually turned on twice a day and debris goes to a dumpster. The manual bar screen is raked as needed, especially during heavy rains. There are plans to upgrade the headworks with a mechanical bar screen & grit removal and remove the screw auger. See summary for details. 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? Page#4 DocuSign Envelope ID: 320836F1-3FE7-47D2-A98A-7F69A1E5B28E Permit:NC0025909 Inspection Date:01/23/2024 Owner - Facility: Inspection Type: Rutherfordton WWTP Compliance Evaluation Equalization Basins Yes No NA NE Are all pumps present? Are all pumps operable? Are float controls operable? Are audible and visual alarms operable? # Is basin size/volume adequate? The EQ basin is primarily storm water, and is used during heavy storm events. A portable pump is used and manually turned on when flow needs to be diverted to the EQ basin. As part of the upgrades, a permanent pump will be installed that will automatically divert flow as needed. Comment: Aeration Basins Yes No NA NE Mode of operation Ext. Air Type of aeration system Surface 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) One or two surface aerators are on at a time. Aeration basin #1 is currently the only basin in use. The liner for aeration basin #2 will be repaired during future upgrades. Once this liner is repaired then the aeration basins can be alternated. At the time of the inspection, Mr. Cabrera measured the DO and it was 1.75 mg/L. Settleability after 45 minutes was around 13%. See summary for details. 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? Is the return rate acceptable (low turbulence)? Page#5 DocuSign Envelope ID: 320836F1-3FE7-47D2-A98A-7F69A1E5B28E Permit:NC0025909 Inspection Date:01/23/2024 Owner - Facility: Inspection Type: Rutherfordton WWTP Compliance Evaluation Secondary Clarifier Yes No NA NE Is the overflow clear of excessive solids/pin floc? Is the sludge blanket level acceptable? (Approximately ¼ of the sidewall depth) The facility has two secondary clarifiers, both of which are used. Flow primarily goes to clarifier #2, but some goes to #1. At the time of the inspection, there was a small amount of excess floating sludge in clarifier #2. Mr. Reynolds indicated that this was because they had just hosed down the clarifier the day prior. The sludge blanket was 2' out of 12' water. The clarifiers are alternated every six months. See summary for details. Comment: Pumps-RAS-WAS Yes No NA NE Are pumps in place? Are pumps operational? Are there adequate spare parts and supplies on site? The facility does not currently have any backup pumps for RAS. They currently have two RAS pumps that they alternate between every three months. As part of the upgrades, a new RAS pump will be purchased. 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? Upgrades will include adding a second digester to be used as a thickener and a new loading station with a containment area for when the sludge is pumped. Sludge is wasted from the secondary clarifiers to the digester approximately once per week. Sludge is wasted from the digester approximately twice a year. Southern Soil Builders land applies the sludge under RLAP Permit WQ0032855. Comment: 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) 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? Page#6 DocuSign Envelope ID: 320836F1-3FE7-47D2-A98A-7F69A1E5B28E Permit:NC0025909 Inspection Date:01/23/2024 Owner - Facility: Inspection Type: Rutherfordton WWTP Compliance Evaluation Disinfection-Liquid Yes No NA NE There are two chlorine contact chambers, but only one side is used at a time and alternated/cleaned every six months. The upgrades include putting the chlorination pumps on SCADA. Comment: 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? # Is de-chlorination substance stored away from chlorine containers? Are the tablets the proper size and type? The chlorination and de-chlorination chemicals are stored in the same room; however, they are in double-walled HDPE chemical bulk storage carboys. Comment: Are tablet de-chlorinators operational? 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? Mr. Reynolds indicated that a new flower meter was installed since the last inspection in 2021. The flow meter was last calibrated on December 5, 2023 by Delta Systems Environmental. 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? Comment: Effluent Sampling Yes No NA NE Is composite sampling flow proportional? Is sample collected below all treatment units? Is proper volume collected? Page#7 DocuSign Envelope ID: 320836F1-3FE7-47D2-A98A-7F69A1E5B28E Permit:NC0025909 Inspection Date:01/23/2024 Owner - Facility: Inspection Type: Rutherfordton WWTP Compliance Evaluation Effluent Sampling Yes No NA NE 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)? The thermometer in the sampling fridge is replaced annually.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? Is the generator fuel level monitored? The generator automatically exercises weekly on Mondays. The fuel tank holds approximately 1,330 gallons of diesel fuel. 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: Page#8 DocuSign Envelope ID: 320836F1-3FE7-47D2-A98A-7F69A1E5B28E