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Home My WebLink AboutNC0046728_Compliance Evaluation Inspection_20240226ROY COOPER Governor ELIZABETH S. BISER Secretary RICHARD E. ROGERS, JR. Director Allison Kraft, Public Utilities Director Town of Mooresville Post Office Box 878 Mooresville, NC 28115 SUBJECT: Compliance Evaluation Inspection NORTH CAROLINA Environmental Quality February 26, 2024 Town of Mooresville/Rocky River WWTP NPDES Permit No. NCO046728 Iredell County Dear Ms. Kraft: Enclosed is a copy of the Compliance Evaluation Inspection (CEI) Report for the inspection conducted at the subject facility on February 20, 2024, by Mr. Wes Bell of this Office. This Office would like to thank all of the Town's wastewater 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(a,deq.nc. gov. Sincerely, DocuSigned by: A�•�Guw H Nil•" F161 FB69A2D84A3... Andrew H. Pitner, P.G., Regional Supervisor Water Quality Regional Operations Section Mooresville Regional Office Division of Water Resources, NCDEQ Enclosure: Inspection Report Cc: NPDES Program Files - Laserfiche f, �-DWE Q North Carolina Department of Environmentat Quality I Division of Water Resources Mooresville Regional Office 1 610 East Center Avenue. Suite 30I 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 NCO046728 I11 121 24/02/20 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 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 permit Number) 09:30AM 24/02/20 19/11/01 Rocky River WWTP 369 Johnson Dairy Rd Exit Time/Date Permit Expiration Date Mooresville NC 28115 01:30PM 24/02/20 24/03/31 Name(s) of Onsite Representative(s)/Titles(s)/Phone and Fax Number(s) Other Facility Data James Levis/ORC/704-662-8341/ Name, Address of Responsible Official/Title/Phone and Fax Number Contacted Jim Landon,PO Box 878 Mooresville NC 28115/Interim Town Manager/704-662-3188/ 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 Wes Bell signed by: DWR/MRO WQ/704-235-2192/ 2/26/2024 2 re& E�D`lc6L 96D90=43T Signature of Ma IsQnA0Rvviewer Agency/Office/Phone and Fax Numbers Date Andrew Pitn LrAs-4"" P4419NR/MRO WQ/704-663-1699 Ext.2180/ 2/26/2024 F161FB69A2D84A3... EPA Form 3560-3 (Rev 9-94) Previous editions are obsolete. Page# NPDES yr/mo/day Inspection Type NC0046728 I11 12I 24/02/20 117 18 i c i Section D: Summary of Finding/Comments (Attach additional sheets of narrative and checklists as necessary) On -site Representatives: The following Town of Mooresville staff were in attendance during the inspection: Mr. Jamie Levis, Mr. Jerry Lyman and Mr. Tony Fritz. Page# Permit: NCO046728 Owner -Facility: Rocky River WWTP Inspection Date: 02/20/2024 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 0 ❑ ❑ ❑ application? Is the facility as described in the permit? 0 ❑ ❑ ❑ # Are there any special conditions for the permit? M ❑ ❑ ❑ Is access to the plant site restricted to the general public? 0 ❑ ❑ ❑ Is the inspector granted access to all areas for inspection? ❑ ❑ ❑ Comment: The Division received the Town's permit renewal package on 10/3/23. The Town implements a Division -approved Industrial Pretreatment Program. The last compliance evaluation inspection at this facility was performed by DWR staff on 3/1/22. Record Keeping 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? Yes No NA NE • ❑ ❑ ❑ • ❑ ❑ ❑ ■ ❑ ❑ ❑ • ❑ ❑ ❑ • ❑ ❑ ❑ ■ ❑ ❑ ❑ ■ ❑ ❑ ❑ ■ ❑ ❑ ❑ ■ ❑ ❑ ❑ ■ ❑ ❑ ❑ ■ ❑ ❑ ❑ • ❑ ❑ ❑ • ❑ ❑ ❑ Page# 3 Permit: NCO046728 Inspection Date: 02/20/2024 Owner -Facility: Rocky 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 January 2023 through December 2023. A weekly average effluent BOD violation was reported in June 2023. The Division has previously addressed this limit violation through the issuance of a Notice of Violation (NOV)/civil penalty assessment. In-depth operation & maintenance records (including process control measurements) were being maintained on -site. 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 (including field) are performed under the Town's on -site certified laboratory certification (#173). Pace Analytical Services and Waypoint Analytical have also been contracted to provide analytical support. The facility staff must ensure that the model and serial numbers for the dissolved oxygen and pH meters are documented on the calibration and field measurement lops. 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? ■ ❑ ❑ ❑ # 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: The subject permit requires influent composite BOD and TSS samples. Sampler aliauot calibrations/verifications are adeauately Derformed (and documented). Effluent Sampling Yes No NA NE Is composite sampling flow proportional? 0 ❑ ❑ ❑ Is sample collected below all treatment units? 0 ❑ ❑ ❑ Is proper volume collected? 0 ❑ ❑ ❑ Is the tubing clean? 0 ❑ ❑ ❑ Page# 4 Permit: NCO046728 Owner -Facility: Rocky River WWTP Inspection Date: 02/20/2024 Inspection Type: Compliance Evaluation Effluent Sampling Yes No NA NE # Is proper temperature set for sample storage (kept at less than or equal to 6.0 0 ❑ ❑ ❑ degrees Celsius)? Is the facility sampling performed as required by the permit (frequency, sampling type 0 ❑ ❑ ❑ representative)? Comment: The subject permit requires composite and grab effluent samples. Sampler aliquot calibrations/verifications are adequately performed (and documented). The facility staff must ensure that oil & grease samples (influent and effluent) are collected directly into the sample container (no intermediate containers) during future sampling events. Upstream / Downstream Sampling Yes No NA NE Is the facility sampling performed as required by the permit (frequency, sampling type, ■ ❑ ❑ ❑ and sampling location)? Comment: The Division has conditionally waived the instream monitoring requirements due to the Town's continued membership in the Yadkin -Pee Dee River Basin Association. Note: The facility staff do perform the quarterly upstream hardness sampling. 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: The wastewater treatment facility appeared to be properly operated and well maintained. The facility staff incorporate an in-depth process control program. The facility is equipped with a SCADA system to assist the wastewater staff in alarm notifications and treatment operations. Equalization Basins Yes No NA NE Is the basin aerated? 0 ❑ ❑ ❑ Is the basin free of bypass lines or structures to the natural environment? 0 ❑ ❑ ❑ Is the basin free of excessive grease? ■ ❑ ❑ ❑ Are all pumps present? 0 ❑ ❑ ❑ Are all pumps operable? 0 ❑ ❑ ❑ Are float controls operable? 0 ❑ ❑ ❑ Are audible and visual alarms operable? ❑ ❑ ■ ❑ # Is basin size/volume adequate? ❑ ❑ ❑ Comment: The facility is equipped with dual one MG equalization tanks. Pump Station - Influent Yes No NA NE Is the pump wet well free of bypass lines or structures? 0 ❑ ❑ ❑ Page# 5 Permit: NC0046728 Owner -Facility: Rocky River WWTP Inspection Date: 02/20/2024 Inspection Type: Compliance Evaluation Pump Station - Influent Yes No NA NE Is the wet well free of excessive grease? 0 ❑ ❑ ❑ Are all pumps present? ■ ❑ ❑ ❑ 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: 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? ■ ❑ ❑ ❑ Is the unit in good condition? 0 ❑ ❑ ❑ Comment: Screenings and grit are disposed by Republic Services at the CMS Landfill. Chemical Feed Yes No NA NE Is containment adequate? 0 ❑ ❑ ❑ Is storage adequate? 0 ❑ ❑ ❑ Are backup pumps available? ■ ❑ ❑ ❑ Is the site free of excessive leaking? ■ ❑ ❑ ❑ Comment: Sodium hydroxide is added to maintain appropriate alkalinity/pH levels. Aeration Basins Yes No NA NE Mode of operation Ext. Air Type of aeration system Diffused Is the basin free of dead spots? 0 ❑ ❑ ❑ Are surface aerators and mixers operational? 0 ❑ ❑ ❑ Are the diffusers operational? ■ ❑ ❑ ❑ Is the foam the proper color for the treatment process? 0 ❑ ❑ ❑ Does the foam cover less than 25% of the basin's surface? 0 ❑ ❑ ❑ Page# 6 Permit: NCO046728 Inspection Date: 02/20/2024 Aeration Basins Is the DO level acceptable? Is the DO level acceptable?(1.0 to 3.0 mg/1) Owner -Facility: Rocky River WWTP Inspection Type: Compliance Evaluation Yes No NA NE • ❑ ❑ ❑ • ❑ ❑ ❑ Comment: The traditional plant is equipped with surface aeration and the package plants (1 MGD each) are equipped with diffused (fine bubble) aeration. 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: The facility is equipped with a total of four (4) secondary clarifiers (2-traditional plant and 2-package plant). Pumps-RAS-WAS Yes No NA NE Are pumps in place? 0 ❑ ❑ ❑ Are pumps operational? ■ ❑ ❑ ❑ Are there adequate spare parts and supplies on site? 0 ❑ ❑ ❑ Comment: 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 Cross flow ❑ ❑ ❑ ❑ ❑ ❑ ❑ ❑ ❑ ❑ ❑ ❑ ❑ ❑ ❑ ■ ❑ ❑ ❑ Page# 7 Permit: NC0046728 Inspection Date: 02/20/2024 Filtration (High Rate Tertiary) Owner -Facility: Rocky River WWTP Inspection Type: Compliance Evaluation Yes No NA NE Comment: The effluent from all four secondary clarifiers is combined prior to the disc -media type filtration system. Disinfection - UV Are extra UV bulbs available on site? Are UV bulbs clean? Is UV intensity adequate? Is transmittance at or above designed level? Is there a backup system on site? Is effluent clear and free of solids? 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 ■ ❑ ❑ ❑ ■ ❑ ❑ ❑ ■ ❑ ❑ ❑ ■ ❑ ❑ ❑ ■ ❑ ❑ ❑ ■ ❑ ❑ ❑ Yes No NA NE ■ ❑ ❑ ❑ ■ ❑ ❑ ❑ ■ ❑ ❑ ❑ ❑ ❑ ■ ❑ Comment: The flow meters (influent and effluent) are calibrated twice per vear and were last calibrated on 1/4/24 by Carolina Technical Services, Inc. Effluent Pipe Yes No NA NE Is right of way to the outfall properly maintained? 0 ❑ ❑ ❑ Are the receiving water free of foam other than trace amounts and other debris? ■ ❑ ❑ ❑ 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. Aerobic Digester 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? Yes No NA NE ■ ❑ ❑ ❑ ■ ❑ ❑ ❑ ■ ❑ ❑ ❑ ■ ❑ ❑ ❑ ■ ❑ ❑ ❑ Page# 8 Permit: NC0046728 Inspection Date: 02/20/2024 Owner -Facility: Rocky River WWTP Inspection Type: Compliance Evaluation Aerobic Digester Yes No NA NE Comment: Both aerobic digesters (aerated sludge holding tanks) were operational and in service. The facility staff are planning on repairing an air leak in the piping system for the digesters within the near future. 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 ■ ❑ ❑ ❑ ■ ❑ ❑ ❑ ■ ❑ ❑ ❑ ■ ❑ ❑ ❑ ■ ❑ ❑ ❑ ■ ❑ ❑ ❑ ■ ❑ ❑ ❑ Comment: The belt press was operational and in service. The dryer system was not in service due to ongoing maintenance. Dewatered bio-solids are either land applied as a Class A product to local farmers or transported to a permitted landfill as a Class B sludge. The facility staff must ensure adequate housekeeping is performed around the dryer building to prevent dewatered sludge from entering the adjacent stormwater drainage system. 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? Yes No NA NE ■ ❑ ❑ ❑ ■ ❑ ❑ ❑ ■ ❑ ❑ ❑ ■ ❑ ❑ ❑ ■ ❑ ❑ ❑ ■ ❑ ❑ ❑ ■ ❑ ❑ ❑ Comment: The facility is equipped with four backup generators (3 - main plant and 1 — equalization tanks). Two generators are required to power the main plant. The generators are tested (automatically) under a simulated load monthly and serviced quarterly by Power Generation & Control. Page# 9