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Home My WebLink AboutNC0074268_Compliance Evaluation Inspection_20240412ROY COOPER Governor ELIZABETH S. BISER Secretary RICHARD E. ROGERS, JR. Director Stephanie Scheringer, Assistant Director of Utilities Two River Utilities P.O. Box 1748 Gastonia, NC 28053-1748 NORTH CAROLINA Environmental Quality April 12, 2024 SUBJECT: Compliance Evaluation Inspection Two Rivers Utilities/Crowders Creek WWTP NPDES Permit No. NCO074268 Gaston County Dear Ms. Scheringer: Enclosed is a copy of the Compliance Evaluation Inspection (CEI) Report for the inspection conducted at the subject facility on April 9, 2024, 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.belIkdeq.nc. gov. Sincerely, EA DocuSigned by: �•�Guw N Pam► F161 F669A2D84A3... 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 el- DEQ�� North Carolina Department of Environmental quality I Divisionof 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 NC0074268 I11 121 24/04/09 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 Dermit Number) 10:OOAM 24/04/09 21/09/01 Crowders Creek WWTP 5642 S York Rd Exit Time/Date Permit Expiration Date Gastonia NC 28052 02:OOPM 24/04/09 26/08/31 Name(s) of Onsite Representative(s)/Titles(s)/Phone and Fax Number(s) Other Facility Data Thomas Carlos Lopez/ORC// Name, Address of Responsible Official/Title/Phone and Fax Number Contacted Michael Peoples,PO Box 1748 Gastonia NC 280531748//704-866-6719/ 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 'Signed by: Wes Bell DWR/MRO WQ/704-235-2192/ 4/12/2024 Be& E�D:,,,�96D90=437 ... Signature of M et9G"Pleviewer Agency/Office/Phone and Fax Numbers Date Andrew Pit e fH P44 �DWR/MRO WQ/704-663-1699 Ext.2180/ 4/12/2024 F161FB69A2D84A3- EPA Form 3560-3 (Rev 9-94) Previous editions are obsolete. Page# NPDES yr/mo/day Inspection Type NC0074268 I11 12I 24/04/09 117 18 i c i Section D: Summary of Finding/Comments (Attach additional sheets of narrative and checklists as necessary) On -site Representatives: The following Two River Utilities' staff were in attendance during the inspection: Ms. Stephanie Scheringer, Mr. David Shellenbarger, Mr. Thomas Lopez, Mr. Charlie Graham and Ms. Susan Copeland. Page# Permit: NCO074268 Owner -Facility: Crowders Creek WWTP Inspection Date: 04/09/2024 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 ❑ ❑ ■ ❑ 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: Two Rivers Utilities implements a Division -approved Industrial Pretreatment Program. The last compliance evaluation inspection at this facility was performed by DWR staff on 3/15/22. 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: NCO074268 Inspection Date: 04/09/2024 Owner -Facility: Crowders Creek 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 March 2023 through February 2024. No limit and/or monitoring violations were reported. In-depth operation and maintenance records including process control measurements were being documented and maintained on -site. Laboratory Yes No NA NE Are field parameters performed by certified personnel or laboratory? 0 ❑ ❑ ❑ 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 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 City of Gastonia — Crowders Creek WWTP laboratory certification #210. Meritech, Inc. (chronic toxicity) and Pace Analytical Services have been contracted to provide analytical support. 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? Yes No NA NE • ❑ ❑ ❑ • ❑ ❑ ❑ • ❑ ❑ ❑ • ❑ ❑ ❑ • ❑ ❑ ❑ ■ ❑ ❑ ❑ Comment: The subject permit requires influent BOD and TSS composite samples. The composite sampler is calibrated monthly (at a minimum) to ensure the programmed aliquot volume is being collected. Effluent Sampling 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)? Yes No NA NE ■ ❑ ❑ ❑ • ❑ ❑ ❑ • ❑ ❑ ❑ • ❑ ❑ ❑ • ❑ ❑ ❑ Page# 4 Permit: NCO074268 Inspection Date: 04/09/2024 Owner -Facility: Crowders Creek WWTP Inspection Type: Compliance Evaluation Effluent Sampling Yes No NA NE Is the facility sampling performed as required by the permit (frequency, sampling type 0 ❑ ❑ ❑ representative)? Comment: The subject permit requires effluent composite and grab samples. The composite sampler is calibrated monthly (at a minimum) to ensure the programmed aliquot volume is being collected. 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? Yes No NA NE ■ ❑ ❑ ❑ Yes No NA NE ❑ ❑ ❑ ❑ ❑ ❑ Comment: The wastewater treatment facility appeared to be properly operated and well maintained. The operations staff incorporate a comprehensive process control program. The facility is equipped with a SCADA system to assist the wastewater staff in alarm notifications and treatment operations. Bar Screens 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: Flow Measurement - Influent # 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 (effluent and influent) are calibrated twice per year and were last calibrated on 2/29/24 by CITI. Inc. Page# 5 Permit: NC0074268 Owner -Facility: Crowders Creek WWTP Inspection Date: 04/09/2024 Inspection Type: Compliance Evaluation Flow Measurement - Influent Yes No NA NE 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? 0 ❑ ❑ ❑ Comment: The grit removal system was temporarily not in service due to pump maintenance/repair. Screenings and grit are disposed at a permitted landfill. Pump Station - Influent Yes No NA NE Is the pump wet well free of bypass lines or structures? 0 ❑ ❑ ❑ Is the wet well free of excessive grease? 0 ❑ ❑ ❑ Are all pumps present? 0 ❑ ❑ ❑ Are all pumps operable? ■ ❑ ❑ ❑ 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? ■ ❑ ❑ ❑ Is the site free of excessive buildup of solids in center well of circular clarifier? ■ ❑ ❑ ❑ Are weirs level? 0 ❑ ❑ ❑ Is the site free of weir blockage? 0 ❑ ❑ ❑ Is the site free of evidence of short-circuiting? 0 ❑ ❑ ❑ Is scum removal adequate? ■ ❑ ❑ ❑ Is the site free of excessive floating sludge? 0 ❑ ❑ ❑ 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) ■ ❑ ❑ ❑ Page# 6 Permit: NCO074268 Inspection Date: 04/09/2024 Owner -Facility: Crowders Creek WWTP Inspection Type: Compliance Evaluation Primary Clarifier Yes No NA NE Comment: Both primaries were operational and in service. Sodium hydroxide is added in the influent prior to the primaries to maintain appropriate alkalinity/pH levels in the downstream treatment processes. Nutrient Removal Yes No NA NE # Is total nitrogen removal required? 0 ❑ ❑ ❑ # Is total phosphorous removal required? E ❑ ❑ ❑ Type Biological # Is chemical feed required to sustain process? 0 ❑ ❑ ❑ Is nutrient removal process operating properly? 0 ❑ ❑ ❑ Comment: The facility is equipped with dual BNR trains consistinq of anaerobic (3 —total), anoxic (4 — total) and oxic (4 — total) basins in each train. Only one BNR train was in service due to low influent flows. Glycerin is added as a carbon supplement and polyaluminum chloride is added to enhance settling and phosphorus removal. Note: Polvaluminum chloride has also been found to control a specific type of filamentous bacteria in the biological treatment process. Aeration Basins Yes No NA NE Mode of operation Ext. Air Type of aeration system 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/1) Comment: 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? Diffused ■ ❑ ❑ ❑ • ❑ ❑ ❑ • ❑ ❑ ❑ • ❑ ❑ ❑ • ❑ ❑ ❑ • ❑ ❑ ❑ • ❑ ❑ ❑ Yes No NA NE • ❑ ❑ ❑ • ❑ ❑ ❑ • ❑ ❑ ❑ • ❑ ❑ ❑ • ❑ ❑ ❑ • ❑ ❑ ❑ Page# 7 Permit: NC0074268 Inspection Date: 04/09/2024 Owner -Facility: Crowders Creek WWTP Inspection Type: Compliance Evaluation Secondary Clarifier Yes No NA NE Is the site free of excessive floating sludge? 0 ❑ ❑ ❑ Is the drive unit operational? 0 ❑ ❑ ❑ Is the return rate acceptable (low turbulence)? ■ ❑ ❑ ❑ Is the overflow clear of excessive solids/pin floc? 0 ❑ ❑ ❑ Is the sludge blanket level acceptable? (Approximately'/4 of the sidewall depth) 0 ❑ ❑ ❑ Comment: Both secondaries were operational and in service. Pumps-RAS-WAS Yes No NA NE Are pumps in place? 0 ❑ ❑ ❑ Are pumps operational? 0 ❑ ❑ ❑ Are there adequate spare parts and supplies on site? ■ ❑ ❑ ❑ Comment: Lagoons Yes No NA NE Type of lagoons? # Number of lagoons in operation at time of visit? 1 Are lagoons operated in? # Is a re -circulation line present? ❑ ❑ 0 ❑ Is lagoon free of excessive floating materials? ■ ❑ ❑ ❑ # Are baffles between ponds or effluent baffles adjustable? ❑ ❑ ■ ❑ Are dike slopes clear of woody vegetation? 0 ❑ ❑ ❑ Are weeds controlled around the edge of the lagoon? 0 ❑ ❑ ❑ Are dikes free of seepage? ■ ❑ ❑ ❑ Are dikes free of erosion? ■ ❑ ❑ ❑ Are dikes free of burrowing animals? 0 ❑ ❑ ❑ # Has the sludge blanket in the lagoon (s) been measured periodically in multiple ❑ ❑ 0 ❑ locations? # If excessive algae is present, has barley straw been used to help control the growth? ❑ ❑ 0 ❑ Is the lagoon surface free of weeds? ■ ❑ ❑ ❑ Is the lagoon free of short circuiting? 0 ❑ ❑ ❑ Comment: The facility is equipped with two polishing ponds (prior to chlorination) that are lined and alternated due to low influent flows. Disinfection -Gas Yes No NA NE Page# 8 Permit: NCO074268 Owner -Facility: Crowders Creek WWTP Inspection Date: 04/09/2024 Inspection Type: Compliance Evaluation Disinfection -Gas Yes No NA NE Are cylinders secured adequately? 0 ❑ ❑ ❑ Are cylinders protected from direct sunlight? 0 ❑ ❑ ❑ Is there adequate reserve supply of disinfectant? ■ ❑ ❑ ❑ Is the level of chlorine residual acceptable? 0 ❑ ❑ ❑ Is the contact chamber free of growth, or sludge buildup? 0 ❑ ❑ ❑ Is there chlorine residual prior to de -chlorination? 0 ❑ ❑ ❑ 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? Comment: Both chlorine contact chamber trains were in service De -chlorination Yes No NA NE Type of system ? Gas Is the feed ratio proportional to chlorine amount (1 to 1)? 0 ❑ ❑ ❑ Is storage appropriate for cylinders? ■ ❑ ❑ ❑ # Is de -chlorination substance stored away from chlorine containers? ❑ ❑ 0 ❑ Are the tablets the proper size and type? ❑ ❑ 0 ❑ Comment: The chlorine and sulfur dioxide cylinders (1 ton) are stored outside under a covered shelter. Following dechlorination, the effluent flows through a post aeration treatment process prior to being discharged into the receiving stream. Are tablet de -chlorinators operational? ❑ ❑ 0 ❑ Number of tubes in use? Comment: 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? 0 ❑ ❑ ❑ If effluent (diffuser pipes are required) are they operating properly? ❑ ❑ ❑ Comment: The effluent appeared clear with no floatable solids and foam (entrained air). The foam dissipated less than fifty (50) yards downstream of the outfall. The receiving stream did not appear to be negatively impacted. Page# 9 Permit: NC0074268 Inspection Date: 04/09/2024 Solids Handling Equipment Is the equipment operational? Is the chemical feed equipment operational? Owner -Facility: Crowders Creek WWTP Inspection Type: Compliance Evaluation 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 facility is equipped with two DAF units for sludge thickening; however, only one DAF was in service. The facilitv is also eauiDDed with a belt Dress that has been taken out of service. 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? Yes No NA NE Floating cover ■ ❑ ❑ ❑ ■ ❑ ❑ ❑ ■ ❑ ❑ ❑ ■ ❑ ❑ ❑ ■ ❑ ❑ ❑ ■ ❑ ❑ ❑ ■ ❑ ❑ ❑ Comment: The facility is equipped with four digesters (1 - primary, 1 - secondary and 2 - holdin tanks). Bio-solids are land applied by a contracted company (EMA Resources) under the authority of Permit No. WQ0001793. Bio-solids can also be transported to the Two Rivers Utilities' Resource Recovery Farm located in Gaston County if land application is hindered due to inclement weather. 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? 0 ❑ ❑ ❑ Was generator tested & operational during the inspection? 0 ❑ ❑ ❑ 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 0 ❑ ❑ ❑ power? Is the generator fuel level monitored? 0 ❑ ❑ ❑ Page# 10 Permit: NC0074268 Inspection Date: 04/09/2024 Standby Power Owner -Facility: Crowders Creek WWTP Inspection Type: Compliance Evaluation Yes No NA NE Comment: The facility is equipped with three backup generators that are all needed to power the entire WWTP. The aenerators are tested twice Der month with one of those tests being under load. The generators are serviced by a contracted company (Carolina CAT) twice per year. Page# 11