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Home My WebLink AboutNC0026573_CEI_20230825 February 19, 2024 Eli Self City of Morganton PO Box 3448 Morganton, NC 28655-9850 SUBJECT: Compliance Inspection Report Catawba River Pollution Control Facility NPDES WW Permit No. NC0026573 Burke County Dear Permittee: The North Carolina Division of Water Resources conducted an inspection of the Catawba River Pollution Control Facility on 8/25/2023. This inspection was conducted to verify that the facility is operating in compliance with the conditions and limitations specified in NPDES WW Permit No. NC0026573. The findings and comments noted during this inspection are provided in the enclosed copy of the inspection report entitled "Compliance Inspection Report". Please respond in writting to this office within 30 days of your receipt of this letter regarding your plans or measures to be taken to address the following issues: 1. Prevention of solids loss during storm flows. 2. Improvement and repair of solids removal processes. 3. Control of solids and BOD loading from SIU’s. DocuSign Envelope ID: DD881761-D9C2-446D-B9C2-5F466B2C4EE2 If you should have any questions, please do not hesitate to contact Melanie Kemp or me with the Water Quality Regional Operations Section in the Asheville Regional Office at 828-296-4500 or via email at melanie.kemp@deq.nc.gov or Daniel.boss@deq.nc.gov. Sincerely, Daniel Boss, Assistant Regional Supervisor Water Quality Regional Operations Section Asheville Regional Office Division of Water Resources, NCDEQ ATTACHMENTS Ec: Laserfiche DocuSign Envelope ID: DD881761-D9C2-446D-B9C2-5F466B2C4EE2 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 NC0026573 23/08/25 C S31112171819 20 21 66 Inspection Work Days Facility Self-Monitoring Evaluation Rating B1 QA ----------------------Reserved------------------- 3 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) Catawba River Pollution Control Facility 1000 Vine Arden Rd Morganton NC 28680 Entry Time/Date Permit Effective Date Exit Time/Date Permit Expiration Date 10:00AM 23/08/25 22/09/01 Name(s) of Onsite Representative(s)/Titles(s)/Phone and Fax Number(s) /// Elisha J Self/ORC/828-438-5376/ Other Facility Data 12:00PM 23/08/25 27/02/28 Name, Address of Responsible Official/Title/Phone and Fax Number Eli Self,PO Box 3448 Morganton NC 286559850/WWTP Superintendent/828-438-5375/ Contacted No Section C: Areas Evaluated During Inspection (Check only those areas evaluated) Permit Flow Measurement Operations & Maintenance Self-Monitoring Program 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 Melanie Kemp DWR/ARO WQ/ - - / Daniel J Boss DWR/ARO WQ/828-296-4658/ 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: DD881761-D9C2-446D-B9C2-5F466B2C4EE2 2/19/2024 2/19/2024 NPDES yr/mo/day 23/08/25 Inspection Type C3111218 1 Section D: Summary of Finding/Comments (Attach additional sheets of narrative and checklists as necessary) On 8/24/2023, Melanie Kemp and I (Daniel Boss) met with Eli Self (ORC) and Tim Arney (BORC) for a Compliance Evaluation Inspection of Morganton WWTP. The facility receives high inflow and infiltration during storm events. Base flow for the facility is about 3.5 MGD. According Mr. Self, storm flows go as high as 30 MGD, but this is not reflected on the eDMR because the WWTP uses empty clarifiers and aeration basins for stormflow retention. In recent months the WWTP has experienced high solids loss during high flows, up to 1000 mg/L of TSS and BOD in the effluent. Alternative operations configurations and parameters should be explored to figure out how to best minimize solids losses during significant storm events. There was one primary clarifier online during the inspeciton. It had a sludge blanket of about 10.5' out of 14' depth. One of the three aeration basins was online. All four secondary clarifiers were online and operational. One of the two chlorine contact chambers was online. According to Mr. Self, they are having difficulty with solids removal, due to a lack of sludge thickening capacity. This is exacerbating the solids pass through during storm flows. A third issue is that two of Morganton's SIU's are sending flows in violations of permit limits, and adding extra solids/food loading on the WWTP. NC0026573 17 (Cont.) Page#2 DocuSign Envelope ID: DD881761-D9C2-446D-B9C2-5F466B2C4EE2 Permit:NC0026573 Inspection Date:08/25/2023 Owner - Facility: Inspection Type: Catawba River Pollution Control Facility Compliance Evaluation 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? Comment: 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: 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: 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? Comment: Page#3 DocuSign Envelope ID: DD881761-D9C2-446D-B9C2-5F466B2C4EE2 Permit:NC0026573 Inspection Date:08/25/2023 Owner - Facility: Inspection Type: Catawba River Pollution Control Facility Compliance Evaluation 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 sampler temperature was 3.0 C. The tubing was dirty but Mr. Arney said it had been replaced just two weeks prior. 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? Is the drive unit operational? Is the sludge blanket level acceptable? Is the sludge blanket level acceptable? (Approximately ¼ of the sidewall depth) There are two primary clarifiers, one is in use. The sludge blanket in the online primary clarifier was 10.5' out of 14' depth. The primary sludge holding tank is not working, the mixer needs to be replaced. Comment: Aeration Basins Yes No NA NE Mode of operation Plug flow 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) Page#4 DocuSign Envelope ID: DD881761-D9C2-446D-B9C2-5F466B2C4EE2 Permit:NC0026573 Inspection Date:08/25/2023 Owner - Facility: Inspection Type: Catawba River Pollution Control Facility Compliance Evaluation Aeration Basins Yes No NA NE There are three aeration basins, two contain fine bubble diffusers and one basin contains three surface aerators. Only one of the diffuser basins needs to be online to treat the wastewater. Mr. Self said the MLSS is kept at about 5000 mg/L in the aeration basin. The settleable solids level at 30 minutes was 68%. 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)? Is the overflow clear of excessive solids/pin floc? Is the sludge blanket level acceptable? (Approximately ¼ of the sidewall depth) All four secondary clarifiers are operational.Comment: Pumps-RAS-WAS Yes No NA NE Are pumps in place? Are pumps operational? Are there adequate spare parts and supplies on site? 1 spare pump on site.Comment: Pure Oxygen Yes No NA NE Type of pure oxygen system Is there a back-up source for the system? Are mixers operational? Are samples port/points easily accessible? The old oxygen system components have been repurposed as storm flow retention tanks. Comment: Disinfection-Gas Yes No NA NE Are cylinders secured adequately? Page#5 DocuSign Envelope ID: DD881761-D9C2-446D-B9C2-5F466B2C4EE2 Permit:NC0026573 Inspection Date:08/25/2023 Owner - Facility: Inspection Type: Catawba River Pollution Control Facility Compliance Evaluation Disinfection-Gas Yes No NA NE 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? Contact chambers accummulate solids quickly. WWTP operators alternate use of contact chambers, draining and cleaning the chambers when solids begin to build up. 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? Comment: Are the tablets the proper size and type? 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? Comment: Effluent Pipe Yes No NA NE Is right of way to the outfall properly maintained? Page#6 DocuSign Envelope ID: DD881761-D9C2-446D-B9C2-5F466B2C4EE2 Permit:NC0026573 Inspection Date:08/25/2023 Owner - Facility: Inspection Type: Catawba River Pollution Control Facility Compliance Evaluation Effluent Pipe Yes No NA NE 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? 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 sampler is programmed for a 60 ml aliquot, but Mr. Arney said the actual volume pulled is 100 ml or more. Comment: Page#7 DocuSign Envelope ID: DD881761-D9C2-446D-B9C2-5F466B2C4EE2