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Home My WebLink AboutNC0024970_Compliance Evaluation Inspection_20240529ROY COOPER Governor ELIZABETH S. BISER Secretary RICHARD E. ROGERS, JR. Director Joseph Lockler, Operations Chief Environmental Management Division Charlotte Water 5100 Brookshire Blvd. Charlotte, NC 28216 SUBJECT: Compliance Evaluation Inspection McAlpine Creek WWMF NPDES Permit No. NCO024970 Mecklenburg County Dear Mr. Lockler: NORTH CAROLINA Environmental Quality May 29, 2024 Enclosed is a copy of the Compliance Evaluation Inspection (CEI) Report for the inspection conducted at the subject facility on May 14, 2024, by Mr. Wes Bell of this Office. This Office would like to thank all Wastewater Management Facility (WWMF) 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, EA DocuSigned by: �•�Guw N Nl-ft 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 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 NCO024970 111 121 24/05/14 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 permit Number) 09:40AM 24/05/14 24/01/01 McAlpine Creek WWTP 12701 Lancaster Hwy Exit Time/Date Permit Expiration Date Pineville NC 28134 01:30PM 24/05/14 28/06/30 Name(s) of Onsite Representative(s)/Titles(s)/Phone and Fax Number(s) Other Facility Data Terrell Reid Smith/ORC/980-800-4888/ Name, Address of Responsible Official/Title/Phone and Fax Number Contacted Angela D Charles,5100 Brookshire Blvd Charlotte NC 282163371//704-336-5911/ 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/ 5/29/2024 2 re& E�D`,','�96D90=437 ... Signature of an tsGAW .viewer Agency/Office/Phone and Fax Numbers Date Andrew Pitn rAr w H P44QANR/MR0 WQ/704-663-1699 Ext.2180/ 5/29/2024 EPA Form 3560-3 (Rev 9-94) Previous editions are obsolete. Page# NPDES yr/mo/day Inspection Type NC0024970 I11 12I 24/05/14 117 18 i c i Section D: Summary of Finding/Comments (Attach additional sheets of narrative and checklists as necessary) On -site Representatives: The following Charlotte Water staff were in attendance during the inspection: Messrs. Darrell DeWitt, Reid Smith, Kevin Sims, Michael Butler, Doug Wise, AZ Williams, and Mike Christiansen. Page# Permit: NCO024970 Owner -Facility: McAlpine Creek WWTP Inspection Date: 05/14/2024 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: Charlotte Water implements a Division -approved Industrial Pretreatment Program. Construction activities associated with the approved Reliability and Process Improvements projects are planned to be completed by the Fall of 2024. The last compliance evaluation inspection at this facility was performed by DWR staff on 2/25/22. 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: NCO024970 Inspection Date: 05/14/2024 Owner -Facility: McAlpine Creek WWTP Inspection Type: Compliance Evaluation Record Keeping Yes No NA NE Comment: The records reviewed durinq the inspection were organized and well maintained. In-depth operation and maintenance records including process control measurements were being documented and maintained on -site. Discharge monitoring reports (eDMRs) were reviewed for the period April 2023 through March 2024. No effluent limit and/or monitoring violations were noted. 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 ❑ ❑ ■ ❑ degrees Celsius)? Incubator (Fecal Coliform) set to 44.5 degrees Celsius+/- 0.2 degrees? ❑ ❑ 0 ❑ Incubator (BOD) set to 20.0 degrees Celsius +/- 1.0 degrees? ❑ ❑ 0 ❑ Comment: Influent and effluent analyses (including field parameters) are performed by Charlotte Water's Environmental Services Laboratory (Certification #192). Waypointe Analytical, ETT Environmental (chronic toxicity) and Environmental Testing Solutions (chronic toxicity) have all 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 sampler operation is checked daily by on -site staff and periodically calibrated. 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 ❑ ❑ ❑ # Is proper temperature set for sample storage (kept at less than or equal to 6.0 ■ ❑ ❑ ❑ degrees Celsius)? Page# 4 Permit: NCO024970 Inspection Date: 05/14/2024 Owner -Facility: McAlpine 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 composite and grab effluent samples. The sampler operation is checked daily by on -site staff and periodically calibrated. Upstream / Downstream Sampling Yes No NA NE Is the facility sampling performed as required by the permit (frequency, sampling type, 0 ❑ ❑ ❑ and sampling location)? Comment: Operations & Maintenance Yes No NA NE Is the plant generally clean with acceptable housekeeping? 0 ❑ ❑ ❑ 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 operations staff incorporate a comprehensive process control program. The facility is equipped with a SCADA system that is accessible at fourteen (14) locations throughout the plant site. Odor control systems are connected to the influent pump station/screening & grit removal facilities, primary clarifiers, sludge thickening/dewatering and bio-solids storage facility. Equalization Basins Yes No NA NE Is the basin aerated? ■ ❑ ❑ ❑ Is the basin free of bypass lines or structures to the natural environment? 0 ❑ ❑ ❑ Is the basin free of excessive grease? 0 ❑ ❑ ❑ Are all pumps present? 0 ❑ ❑ ❑ Are all pumps operable? 0 ❑ ❑ ❑ Are float controls operable? 0 ❑ ❑ ❑ Are audible and visual alarms operable? ❑ ❑ 0 ❑ # Is basin size/volume adequate? E ❑ ❑ ❑ Comment: The facility is equipped with an eighty-five (85) million gallon equalization basin. Excess influent flows from Charlotte Water's Irwin Creek and Sugar Creek wastewater treatment facilities can also be diverted to this equalization basin. Bar Screens Type of bar screen a.Manual Yes No NA NE u Page# 5 Permit: NC0024970 Owner -Facility: McAlpine Creek WWTP Inspection Date: 05/14/2024 Inspection Type: Compliance Evaluation Bar Screens Yes No NA NE b.Mechanical Are the bars adequately screening debris? ■ ❑ ❑ ❑ Is the screen free of excessive debris? 0 ❑ ❑ ❑ 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 ❑ ❑ ❑ Is the grit free of excessive odor? 0 ❑ ❑ ❑ # Is disposal of grit in compliance? 0 ❑ ❑ ❑ Comment: Screenings and grit are disposed at the CMS Landfill located in Concord, N.C. by Republic Services. Pump Station - Influent Is the pump wet well free of bypass lines or structures? Is the wet well free of excessive grease? Are all pumps present? Are all pumps operable? Are float controls operable? Is SCADA telemetry available and operational? Is audible and visual alarm available and operational? Comment: Primary 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? Yes No NA NE • ❑ ❑ ❑ • ❑ ❑ ❑ • ❑ ❑ ❑ • ❑ ❑ ❑ • ❑ ❑ ❑ • ❑ ❑ ❑ ❑ ❑ ■ ❑ Yes No NA NE • ❑ ❑ ❑ • ❑ ❑ ❑ • ❑ ❑ ❑ • ❑ ❑ ❑ • ❑ ❑ ❑ Page# 6 Permit: NCO024970 Inspection Date: 05/14/2024 Owner -Facility: McAlpine Creek WWTP Inspection Type: Compliance Evaluation Primary Clarifier Yes No NA NE Is scum removal adequate? 0 ❑ ❑ ❑ 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) 0 ❑ ❑ ❑ Comment: All eight primary clarifiers (4 — North train and 4 — South Train) were operational and in service. Nutrient Removal Yes No NA NE # Is total nitrogen removal required? 0 ❑ ❑ ❑ # Is total phosphorous removal required? 0 ❑ ❑ ❑ Type Biological # Is chemical feed required to sustain process? 0 ❑ ❑ ❑ Is nutrient removal process operating properly? 0 ❑ ❑ ❑ Comment: Two aeration basins in the North Train have been converted to fermenters to enhance nutrient reductions. Ferric chloride is also added in the South Train (and North Train as -needed) prior to the secondaries for nutrient reductions. 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? ■ ❑ ❑ ❑ 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) ■ ❑ ❑ ❑ Comment: All twenty-six (26) aeration basins (10 — North Train and 16 — South Train) were in service. Each aeration basin is equipped with an anaerobic zone and multiple oxic zones. Magnesium hydroxide is added to maintain appropriate alkalinity/pH levels. Foam covered more than 25% of the basins; however, no foam carryover was observed in the secondaries. Secondary Clarifier Yes No NA NE Is the clarifier free of black and odorous wastewater? 0 ❑ ❑ ❑ Page# 7 Permit: NCO024970 Owner -Facility: McAlpine Creek WWTP Inspection Date: 05/14/2024 Inspection Type: Compliance Evaluation Secondary Clarifier Yes No NA NE 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) ■ ❑ ❑ ❑ Comment: All sixteen (16) secondary clarifiers (6 — North Train and 10 — South Train) were in service. Pumps-RAS-WAS Yes No NA NE Are pumps in place? ■ ❑ ❑ ❑ Are pumps operational? ■ ❑ ❑ ❑ Are there adequate spare parts and supplies on site? ■ ❑ ❑ ❑ Comment: Chemical Feed Yes No NA NE Is containment adequate? ■ ❑ ❑ ❑ Is storage adequate? ■ ❑ ❑ ❑ Are backup pumps available? ■ ❑ ❑ ❑ Is the site free of excessive leaking? ■ ❑ ❑ ❑ Comment: Filtration (High Rate Tertiary) Yes No NA NE Type of operation: Down flow 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? ■ ❑ ❑ ❑ Page# 8 Permit: NC0024970 Owner -Facility: McAlpine Creek WWTP Inspection Date: 05/14/2024 Inspection Type: Compliance Evaluation Filtration (High Rate Tertiary) Yes No NA NE Comment: All nineteen (19) tertiary filters were in service. Disinfection -Liquid Yes No NA NE Is there adequate reserve supply of disinfectant? 0 ❑ ❑ ❑ (Sodium Hypochlorite) Is pump feed system operational? 0 ❑ ❑ ❑ Is bulk storage tank containment area adequate? (free of leaks/open drains) ■ ❑ ❑ ❑ 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 ❑ ❑ ❑ Comment: Both chlorine contact chamber trains were in service. Flow Measurement - Effluent Yes No NA NE # Is flow meter used for reporting? 0 ❑ ❑ ❑ Is flow meter calibrated annually? 0 ❑ ❑ ❑ Is the flow meter operational? 0 ❑ ❑ ❑ (If units are separated) Does the chart recorder match the flow meter? ❑ ❑ 0 ❑ Comment: The flow meter is calibrated twice per year and was last calibrated on 2/19/24 by CITI, LLC. De -chlorination Yes No NA NE Type of system ? Liquid 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: Aqueous sodium bisulfite is used for dechlorination. 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 ❑ ❑ ❑ Page# 9 Permit: NCO024970 Owner -Facility: McAlpine Creek WWTP Inspection Date: 05/14/2024 Inspection Type: Compliance Evaluation Effluent Pipe Yes No NA NE If effluent (diffuser pipes are required) are they operating properly? ❑ ❑ 0 ❑ Comment: The effluent appeared clear with no floatable solids and foam (entrained air). The foam dissipates prior to the Lancaster Hwy. bridge. 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? Yes No NA NE Fixed cover • ❑ ❑ ❑ • ❑ ❑ ❑ • ❑ ❑ ❑ • ❑ ❑ ❑ • ❑ ❑ ❑ • ❑ ❑ ❑ • ❑ ❑ ❑ Comment: Six of the eight anaerobic digesters and one of the two storage tanks were in service. One of the digesters was in the process of being cleaned out and a second digester was being evaluated for repairs. 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: Six centrifuges (3 —thickening and 3 — dewatering) were operational. Three of the four gravity thickeners were in service. Dewatered bio-solids are land applied by Synagro under the authority of Permit No. WQ0000057. The Division received an application for an Authorization to Construct (AtC) from Charlotte Water on 4/29/24 for the construction of a Nutrient Harvesting Facility. The AtC is currently under review. 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# 10 Permit: NC0024970 Owner -Facility: McAlpine Creek WWTP Inspection Date: 05/14/2024 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? 0 ❑ ❑ ❑ Comment: The facility is equipped with six generators that are serviced quarterly by Cummings. Page# 11