NC0024201_Historical information_20091231

OCT _9?009
September 29, 2009
Subject:
Dear Mr. Brown:
A letter of request for an Authorization to Construct was received June 4, 2009, by the
Division of Water Quality (Division), and final plans and specifications for the subject project
have been reviewed and found to be satisfactory. Authorization is hereby granted for the
construction of modifications to the existing 8.34 MGD Wastewater Treatment Plant, with
discharge of treated wastewater into the Roanoke River in the Roanoke River Basin.
Mr. R. Danieley Brown, P.E.
Roanoke Rapids Sanitary District
1000 Jackson Street
Roanoke Rapids, North Carolina 27870
This authorization results in no increase in design or permitted capacity and is awarded
for the construction of the following specific modifications:
Beverly Eaves Perdue
Governor
Installation of a new sodium hypochlorite bulk storage and feed facility consisting
of two (2) 13,680 gallon bulk hypochlorite storage tanks, two (2) 45 GPH
metering feed pumps, and two (2) 100 GPM magnetic drive hypochlorite
recirculation pumps; a dechlorination system consisting of a 4,470 gallon bulk
sodium bisulphite storage tank and two (2) 3 GPH metering feed pumps; a 1,645
gallon sodium hydroxide bulk storage tank and two (2) 6 GPH metering feed
pumps; a contact chamber drain submersible pump, demolition of existing
chlorine and sulfur dioxide disinfection system, and all necessary piping and
appurtenances, in conformity with the project plans, specifications, and other
supporting data subsequently filed and approved by the Department of
Environment and Natural Resources.
Dee Freeman
Secretary
1617 Mail Service Center, Raleigh, North Carolina 27699-1617
Location: 512 N. Salisbury St. Raleigh, North Carolina 27604
Phone: [phone] \ FAX: [phone] \ Customer Service: 1-877-623-6748
Internet: www.ncwaterquality.org
An Equal Opportunity \ Affirmative Action Employer
r
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NorthCarolinaNaturally
Authorization to Construct
A to C No. 024201A02
Roanoke Rapids Sanitary District
Roanoke Rapids Sanitary District WWTP
Halifax County
NCDENR
North Carolina Department of Environment and Natural Resources
Division of Water Quality
Coleen H. Sullins
Director
During the construction of the proposed additions/modifications, the permittee shall
continue to properly maintain and operate the existing wastewater treatment facilities at all times,
Upon classification of the facility by the Certification Commission, the Permittee shall
employ a certified wastewater treatment plant operator to be in responsible charge (ORC) of the
wastewater treatment facilities. The operator must hold a certificate of the type and grade at
least equivalent to or greater than the classification assigned to the wastewater treatment
facilities by the Certification Commission.
The Permittee must also employ a certified back-up operator of the appropriate type and
grade to comply with the conditions of T15A:8G.O2O2. The ORC of the facility must visit each
Class I facility at least weekly and each Class II, III and IV facility at least daily, excluding
weekends and holidays, must properly manage the facility, must document daily operation and
maintenance of the facility, and must comply with all other conditions of T15A:8G.O2O2.
A copy of the approved plans and specifications shall be maintained on file by the
Permittee for the life of the facility.
In the event that the facilities fail to perform satisfactorily, including the creation of
nuisance conditions, the Permittee shall take immediate corrective action, including those as may
be required by the Division, such as the construction of additional or replacement wastewater
treatment or disposal facilities.
This Authorization to Construct is issued in accordance with Part III, Paragraph A of
NPDES Permit No. NC0024201 issued June 12, 2007, and shall be subject to revocation unless
the wastewater treatment facilities are constructed in accordance with the conditions and
limitations specified in Permit No. NC0024201.
The sludge generated from these treatment facilities must be disposed of in accordance
with G.S. 143-215.1 and in a manner approved by the Division.
Mr. R. Danieley Brown, P.E.
September 29, 2009
Page 2
The Raleigh Regional Office, telephone number [phone], shall be notified at
least forty-eight (48) hours in advance of operation of the installed facilities so that an on site
inspection can be made. Such notification to the regional supervisor shall be made during the
normal office hours from 8:00 a.m. until 5:00 p.m. on Monday through Friday, excluding State
Holidays.
Upon completion of construction and prior to operation of this permitted facility, a
certification must be received from a professional engineer certifying that the permitted facility
has been installed in accordance with the NPDES Permit, this Authorization to Construct and the
approved plans and specifications. Mail the Certification to: Construction Grants & Loans,
DWQ/DENR, 1633 Mail Service Center, Raleigh, NC 27699-1633.
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The issuance of this Authorization to Construct does not preclude the Permittee from
complying with any and all statutes, rules, regulations, or ordinances which may be imposed by
other government agencies (local, state, and federal) which have jurisdiction.
You are reminded that it is mandatory for the project to be constructed in accordance
with the North Carolina Sedimentation Pollution Control Act, and when applicable, the North
Carolina Dam Safety Act. In addition, the specifications must clearly state what the contractor’s
responsibilities shall be in complying with these Acts.
Prior to entering into any contract(s) for construction, the recipient must have obtained all
applicable permits from the State.
Mr. R. Danieley Brown, P.E.
September 29, 2009
Page 3
Failure to abide by the requirements contained in this Authorization to Construct may
subject the Permittee to an enforcement action by the Division in accordance with North
Carolina General Statute 143-215.6A to 143-215.6C.
and in such a manner, as necessary to comply with the effluent limits specified in the NPDES
Permit.
Sincerely,
Coleen H. Sullins
One (1) set of approved plans and specifications is being forwarded to you. If you have
any questions or need additional information, please contact Seth Robertson, P.E. at telephone
number [phone].
Miranda W. Spencer, P.E. - ARCADIS, 801 Corporate Center Dr., Suite 300,
Raleigh, NC 27607
Halifax County Health Department
DWQ Raleigh Regional Office, Surface Water Protection
Technical Assistance and Certification Unit
Point Source Branch, NPDES Program
Steve Tsadwa
SRF File
Engineer’s Certification
Signature Registration No..
Date
Send to:
I certify that the construction of the above referenced project was observed to be built
within substantial compliance and intent of the approved plans and specifications.
Installation of a new sodium hypochlorite bulk storage and feed facility consisting
of two (2) 13,680 gallon bulk hypochlorite storage tanks, two (2) 45 GPH
metering feed pumps, and two (2) 100 GPM magnetic drive hypochlorite
recirculation pumps; a dechlorination system consisting of a 4,470 gallon bulk
sodium bisulphite storage tank and two (2) 3 GPH metering feed pumps; a 1,645
gallon sodium hydroxide bulk storage tank and two (2) 6 GPH metering feed
pumps; a contact chamber drain submersible pump, demolition of existing
chlorine and sulfur dioxide disinfection system, and all necessary piping and
appurtenances, in conformity with the project plans, specifications, and other
supporting data subsequently filed and approved by the Department of
Environment and Natural Resources.
Roanoke Rapids Sanitary District
A To C No. 024201A02
Project No. CS370449-04
Issued September 29, 2009
Construction Grants & Loans
DENR/DWQ
1633 Mail Service Center
Raleigh, NC 27699-1633
I,, as a duly registered Professional Engineer in
the State of North Carolina, having been authorized to observe (periodically/weekly/full time)
the construction of the modifications and improvements to the Roanoke Rapids Sanitary District
WWTP, located on 135 Aqueduct Road, Weldon in Halifax County for the Roanoke Rapids
Sanitary District, hereby state that, to the best of my abilities, due care and diligence was used in
the observation of the following construction:
September 29, 2009
Subject:
Dear Mr. Brown:
Eligible
Non Eligible
Issuance of this approval letter does not imply availability of funding. In the event that
received bids exceed the amount established through the funding offer, and local funds are not
adequate to award contract(s), it will be necessary to consider all alternatives including redesign,
re-advertising, and rebidding.
A new sodium hypochlorite bulk storage and feed facility consisting of two (2) 13,680 gallon
bulk hypochlorite storage tanks, two (2) 45 GPH metering feed pumps, and two (2) 100 GPM
magnetic drive hypochlorite recirculation pumps; a dechlorination system consisting of a 4,470
gallon bulk sodium bisulphite storage tank and two (2) 3 GPH metering feed pumps; a 1,645
gallon sodium hydroxide bulk storage tank and two (2) 6 GPH metering feed pumps; a contact
chamber drain submersible pump, demolition of existing chlorine and sulfur dioxide disinfection
system, and all necessary piping and appurtenances.
Any costs associated with choosing the Alternative Owner Preferred Major Equipment Items above
the Base Bid costs are deemed non-eligible for Revolving Loan funding.
The review for completeness and adequacy of the project construction plans and
specifications has been concluded by the Construction Grants & Loans Section of the North
Carolina Division of Water Quality. Therefore, said plan documents are hereby approved.
Eligibility for Revolving Loan funding is determined as follows:
Mr. R. Danieley Brown, P.E.
Roanoke Rapids Sanitary District
1000 Jackson Street
Roanoke Rapids, North Carolina 27870
Beverly Eaves Perdue
Governor
Dee Freeman
Secretary
1633 Mail Service Center, Raleigh, North Carolina 27699-1633
Location: 2728 Capital Blvd. Raleigh, North Carolina 27604
Phone: [phone] \ FAX: [phone] \ Customer Service: 1 -877-623-6748
Internet: www ncwaterquality.org
An Equal Opportunity \ Affirmative Action Employer
HCDEHR
North Carolina Department of Environment and Natural Resources
Division of Water Quality
Coleen H. Sullins
Director
NorthCarolina
Naturally
Roanoke Rapids Sanitary District
Roanoke Rapids Sanitary District WWTP
WWTP Improvements
Approval of the Plans and Specifications
Project No. CS370449-04
Any addenda to be issued for subject project plans and specifications must be submitted by
the Recipient such that adequate time is allowed for review/approval action by the State, and for
subsequent bidder action prior to receipt of bids.
It is mandatory for project facilities to be constructed in accordance with the North
Carolina Sedimentation Pollution Control Act, and, when applicable, the North Carolina Dam
Safety Act. In addition, the specifications must clearly state what the contractors' responsibilities
shall be in complying with these Acts.
Prior to entering into any contract(s) for construction, the recipient must have obtained all
applicable project Permits from the State, including an Authorization to Construct and/or Non­
Discharge Permit.
While rejection of all bids is possible, such action may be taken only with prior State
concurrence, and only for good cause.
It is the responsibility of the Recipient and the Consulting Engineer to insure that the
project plan documents are in compliance with Amended N. C. G. S. 133-3 (ratified July 13,
1993). The administrative review and approval of these plans and specifications, and any
subsequent addenda or change order, do not imply approval of a restrictive specification for
bidding purposes; nor is it an authorization for noncompetitive procurement actions.
Your project is subject to the one-year performance certification requirements. By this,
you are required on the date one year after the completion of construction and initial operation of
the subject treatment facilities, to certify, based on your consulting engineer's advisement,
whether or not such treatment works meet the design performance, specifications and the permit
conditions and effluent limitations.
Neither the State nor Federal Government, nor any of its departments, agencies or
employees is or will be a party to the invitation to bids, addenda, any resulting contracts or
contract negotiations/changes.
If the Recipient does not maintain the court sanctioned schedules which extended the
compliance date for complying with the final effluent limits established in the NPDES Permit,
then project costs incurred will not be eligible for Revolving Loan payments.
Mr. R. Danieley Brown, P.E.
September 29, 2009
Page Number 2
In accordance with the Federal Regulations, the Recipient is required to assure compliance
with the OSHA safety regulations on the subject project. In complying with this regulatory
responsibility, the Recipient should, by letter, invite the Bureau Chief, Education Training and
Technical Assistance Unit, NC OSHA Division, 1101 Mail Service Center, Raleigh, NC 27699-
1101 at [phone], to participate in the Preconstruction Conference to assure that proper
emphasis is given on understanding and adhering to the OSHA regulations.
Do not proceed with construction until the Authorization-to-Award package and the EEO
and MBE documentation/certification have been reviewed, and you are in receipt of our
approval, if a Federal loan is desired for project construction.
Two (2) copies of any change order must be promptly submitted by the Recipient to the
State. If additional information is requested by the State, a response is required within two (2)
weeks, or the change order will be returned without further or final action.
A goal of 8% of the contract price is established for Minority Business Enterprise (MBE)
participation in this project, and a goal of 5% of the contract price is established for Women's
Business Enterprise (WBE) participation in this project. The Recipient and Bidders shall make a
good faith effort to assure that MBE's and WBE's are utilized, when possible, as sources of
goods and services. The good faith effort must include the following affirmative steps: (a)
including small, minority, and women's businesses on solicitation lists; (b) assuring that small,
minority, and women's businesses are solicited whenever they are potential sources; (c) dividing
total requirements, when economically feasible, into small tasks or quantities to permit
maximum participation by small, minority, and women's businesses; (d) establishing delivery
schedules, and (e) using the services of the Small Business Administration and the Minority
Business Development Agency of the U.S. Department of Commerce. Please note that the
solicitation efforts should include documentable follow-up phone calls.
The Recipient shall comply with the provisions of 40 CFR, Part 7, Subpart C -
Discrimination Prohibited on the Basis of Handicap.
Mr. R. Danieley Brown, P.E.
September 29, 2009
Page Number 3
Upon completion of the project construction, the Recipient shall submit a letter confirming
that the project has been constructed in accordance with the plans and specifications approved by
the State. "As-built" plans will need to be submitted with any changes clearly documented on
the plans if the above confirmation cannot be made.
One (1) set of the final approved plans and specifications will be forwarded to you. One
(1) set of plans and specifications identical to the approved set must be available at the project
site at all times.
Attached is one (1) copy of the Project Bid Information (Authority to Award) which is to
be completed within 21 days after bids have been received, and submitted to the State for review.
Upon review and approval of this information, the State will authorize the Recipient to make the
proposed award.
I.
Attachment
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If there are any questions concerning this matter, please do not hesitate to contact
Seth Robertson, P.E. at [phone].
Mr. R. Danieley Brown, P.E.
September 29, 2009
Page Number 4
Sincerely,
Daniel M. Blaisdell, P.E., Section Chief
Construction Grants & Loans Section
Miranda W. Spencer, P.E. - ARC ADIS, 801 Corporate Center Dr., Suite 300,
Raleigh, NC 27607
OSHA Bureau Chief, Wanda Lagoe
DWQ Raleigh Regional Office
Mark Hubbard, P.E.
Steve Tsadwa
CIG
SRF
□I
June 5, 2009
North Carolina Division of Water Quality
cc: RRO-SWP File
Central Files
Mr. R. Danieley Brown, CEO
Roanoke Rapids Sanitary District
P.O. Box 308
Roanoke Rapids, NC 27870
Beverly Eaves Perdue
Governor Dee Freeman
Secretary
Subject: Compliance Evaluation Inspections
Roanoke Rapids Sanitary District
NPDES Permit No. NC0024201
and Stormwater Permit No. NCG110091
Halifax County
Surface Water Protection
Raleigh, NC 27699-1628
. ....— -------Raleigh Regional Office Surface Water Protection Phone [phone]nnInternet, www.ncwaterquahty.org 1628 Mail Service Center Raleigh, NC 27699-1628 FAX (919) 7^59
An Equal Opportunity/Affirmative Action Employer - 50% Recycled/10% Post Consumer Paper
NorthCarolina— Naturally
Customer Service
877-623-6748
Piease find the summarized results of the Inspection in the attached Inspection Report. The Subiect
Facility is in compliance and well-maintained.
The Roanoke Rapids WWTP is a Class IV Facility, located at 135 Aqueduct Road near Weldon in
Halitax County, North Carolina and discharges to the Roanoke River, a class C water in the Roanoke
ver Basin. The Facility’s process includes the following components: bar screen, grit chamber dual
primary clarifiers, dual trickling filters, three (3) aeration basins, dual secondary clarifiers three (3)
anaerobic digesters, sludge thickener, lime stabilization, sludge drying beds, gas chlorination and de-
chlorination and related contact chamber.
NCDENR
North Carolina Department of Environment and Natural Resources
Division of Water Quality
Coleen H. Sullins
Director
Sincerely,
Kwxi
Myrl A. Nisely
Environmental Chemist
The Facility s Stormwater program is implemented and compliant. Please see the attached checklist,
ontinued efforts by the Facility to construct and maintain observation platforms are commendable.
If you should have questions, please contact me at [phone].
On May 19 2009, Myrl Nisely and Mandy Hall of the Raleigh Regional Office conducted a Compliance
valuation Inspection of the Subject facility. The cooperation and assistance of Gregg Camp. ORC and
Greta Glover, BORC were greatly appreciated.
MAILED
EPA
NPDES
NC0024201
| | | | | | | | | | | | | | | [66
Entry Time/Date Permit Effective Date
07/07/01
Exit Time/Date Permit Expiration Date
12/03/31
Other Facility Data
Alan Gregg Camp/ORC/919-536-4884/
Greta Glover/ORC/919-536-4884/
(See attachment summary)
Name(s) and Signature(s) of Inspector(s)Agency/Office/Phone and Fax Numbers
Mandy RRO WQ//919-791-4200/
RRO WQ//919-791-4200/
Agency/Office/Phone and Fax Numbers
UK
;olete.
Page #1
1213[
Water Compliance Inspection Report
Section A: National Data System Coding (i.e., PCS)
Roanoke Rapids WWTP
135 Aqueduct Rd
Weldon NC 27890
Areas Evaluated During Inspection (Check only those areas evaluated)
Records/Reports
I Effluent/Receiving Waters
United States Environmental Protection Agency
Washington, D.C. 20460
Operations & Maintenance
■ Facility Site Review
yr/mo/day
09/05/19
Form Approved.
OMB No. 2040-0057
Approval expires 8-31-98
Contacted
No
Facility Self-Monitoring Evaluation Rating
___ 70U
QA
72H
Name(s) of Onsite Representative(s)fTitles(s)/Phone and Fax Number(s)
///
Date
J11 J17
Fac Type
20IJ
Inspection Type
18L£|
Inspector
19hJ
Transaction Code
1 HJ 2 Lil
—Reserved---------------------
75l I I I I I I lso73l I I74
Myrl Wisely f\\C[
jQ-----— ^7
Signature of Management Q A Revli
EPA Form 3560-3 (Rev 9-94) Previous editions are ol
■ Permit
|| Self-Monitoring Program
| Laboratory
Section D:
B1 71 u
___________________ Section B: Facility Data
“m/SKpDES lndUSWa' USCre diSChar9in9,0 P0™'' alS° indUde
Name, Address of Responsible Official/Title/Phone and Fax Number
RaE’ld8 Nc
Remarks
I I I N I I I I I I N | | | | | | | | | I I I I I I I I |
Inspection Work Days
67] | 69
Section C:
| Flow Measurement
Sludge Handling Disposal
Storm Water
Summary of Finding/Comments (Attach additional sheets of narrative and checklists as necessary)
10:00 AM 09/05/19
12:10 PM 09/05/19
NPDES yr/mo/day 1
I17NC002420109/05/19
Section D:
Page#2
3I I11 ,2I
Sludgo generated by the facility is removed by Synagro and land-applied in Halifax, Northampton and
Warren Counties. Roanoke Rapids Sanitary District owns a portion of this land.
The Sludge Thickener was recently cleaned and is on a 10-year maintenance cycle.
Inspection Type
18i i
l£j
Summary of Finding/Comments (Attach additional sheets of narrative and checklists as necessary)
Facility is compliant and well-maintained.
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:Current Permit expires in 2012.
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?
Yes No NA NE
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?■ ODD
Is SCADA telemetry available and operational?■
Is audible and visual alarm available and operational?■
Comment:N/A
Pri m a ry Ci ar if ie r 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?■ O
Is the sludge blanket level acceptable?■
Page #3
Owner - Facility: Roanoke Rapids WWTP
Inspection Type: Compliance Evaluation
Permit: NC0024201
Inspection Date: 05/19/2009
Comment: Facility grounds were well-maintained. There was a painting project
occurring in the Anaerobic Digester building at the time of inspection.
Pump Statiorr- Influent
Primary Clarifier Yes No NA NE
■
Trickling Filter Yes No NA NE
Is the filter free of ponding?■
Is the filter free of leaks at the center column of filter’s distribution arms?■ O
Is the distribution of flow even from the distribution arms?■
Is the filter free of uneven or discolored growth?■
Is the filter free of sloughing of excessive growth?■
Are the filter's distribution arms orifices free of clogging?■
Is the filter free of excessive filter flies, worms or snails?■
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)■
Comment:N/A
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?■
Page #4
Permit: NC0024201
Inspection Date: 05/19/2009
Owner - Facility: Roanoke Rapids WWTP
Inspection Type: Compliance Evaluation
Is the sludge blanket level acceptable? (Approximately 74 of the sidewall depth)
Comment: Mr. Camp indicated rehabilitation work will be done to the Primary Clarifiers
in the next 6 months to 1 year. The sludge blanket depth is ~4 ft. on average. Primary
clarifiers are cleaned as needed.
Comment: Trickling Filter surfaces were free and clear of debris. The Influent
Distribution System is efficient at equally distributing the flow across the media.
Aeration Basins
Secondary Clarifier Yes No NA NE
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?■
■
Yes No NA NE
Type of operation:Floating cover
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
Is there adequate drying bed space?■
Is the sludge distribution on drying beds appropriate? ■
Are the drying beds free of vegetation?■
# Is the site free of dry sludge remaining in beds?■
Is the site free of stockpiled sludge?■
Is the filtrate from sludge drying beds returned to the front of the plant?O ■
# Is the sludge disposed of through county landfill?■
# Is the sludge land applied?■
(Vacuum filters) Is polymer mixing adequate? O ■
Comment:
Yes No NA NE
Page #5
Drying beds are only used for emerency situations.
Disinfection-Gas
Permit: NC0024201
Inspection Date: 05/19/2009
Owner - Facility: Roanoke Rapids WWTP
Inspection Type: Compliance Evaluation
Is the sludge blanket level acceptable^ (Approximately 1/« of the sidewall depth)
Comment: Facility has rectangular Secondary Clarifiers.
Anaerobic Digester
Comment: Gas produced by the Anaerobic Digester is used for heating the Digester
The Digesters were recently cleaned and are on a 7-10 year schedule.
Drying Beds
Disinfection-Gas Yes No NA NE
Are cylinders secured adequately?■
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?■
■
■
If yes, then what is the EPA twelve digit ID Number? (1000-.0006-3068J
If yes, then when was the RMP last updated?10/30/2003
In the latter part of 2009, the facility will change to liquid bleach Disinfection
De-chlorination Yes No NA NE
Type of system ?Gas
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? ■
Comment:N/A
Are tablet de-chlorinators operational? ■
Number of tubes in use?
Comment:N/A
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?■ O
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
Page #6
Comment: I "
from Chlorine Gas.
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?
Permit: NC0024201
Inspection Date: 05/19/2009
Owner - Facility: Roanoke Rapids WWTP
Inspection Type: Compliance Evaluation
Record Keeping Yes No NA NE
Results of analysis and calibration
Dates of analysis
Name of person performing analyses
Transported COCs
Are DM Rs complete: do they include all permit parameters?■
Has the facility submitted its annual compliance report to users and DWQ?■
■
■
higher than the facility classification?■
■
■
■
Greta Glover and Bryan Williams are Back-Up Operators-in-Responsible
Page #7
grade less or greater than the facility classification?
Is a copy of the current NPDES permit available on site?
Permit: NC0024201
Inspection Date: 05/19/2009
Owner - Facility: Roanoke Rapids WWTP
Inspection Type: Compliance Evaluation
(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?
Facility has copy of previous year's Annual Report on file for review?
Comment:
Charge.
Is the backup operator certified at one
Is the ORC certified at grade equal to or
May 7, 2009
SUBJECT:
Dear Mr. Brown:
The subject Roanoke Rapids Sanitary District Engineering Report is hereby approved.
The Construction Grants and Loans Section of the Division of Water Quality has
completed its review of the subject Roanoke Rapids Sanitary District Engineering Report. The
proposed project located at the Roanoke Rapids WWTP, involves replacing the existing gas
chlorine disinfection system and dechlorination system with a new Sodium Hypochlorite liquid
feed system and Sodium Bisulphite dechlorination system. The project involves two new bulk
storage tanks and chemical feed pumps for liquid Sodium Hypochlorite to be housed in a
concrete secondary containment structure enclosed by a pre-engineered steel building, and a
chemical truck spill containment vault.
Beverly Eaves Perdue
Governor
Mr. R. Danieley Brown, P.E.
Chief Executive Officer
Roanoke Rapids Sanitary District
Post Office Box 27870
Roanoke Rapids, North Carolina 27870
Approval - Engineering Report for
Roanoke Rapids Sanitary District
Roanoke Rapids Wastewater Treatment Plant
Sodium Hypochlorite System
February 2009
Project No. CS370449-04
Dee Freeman
Secretary
1633 Mail Service Center. Raleigh, North Carolina 27699-1633
Location 2728 Capital Blvd. Raleigh. North Carolina 27604
Phone: [phone] \ FAX: [phone] \ Customer Service 1-877-623-6748
Internet www ncwaterquality.org
An Equal Opportunity \ Affirmative Action Employer
Plle i 1 •NorthCarolinaNaturally
NCDENR
North Carolina Department of Environment and Natural Resources
Division of Water Quality
Coleen H. Sullins
Director
Sincerely,
mwl:dr
cc:
If you have any questions concerning this matter, please contact Michael Leggett, E.I. of
our staffat [phone].
Mr. R. Danieley Brown, P.E.
April 28, 2009
Page 2
ARCAD1S - Miranda W. Spencer, P.E.
DWQ Raleigh Regional Office
Kim Colson, P.E.
Jennifer Haynie - FEU Supervisor
Michael Leggett, E.I.
FEU/SRF
*
Daniel M. Blaisdell, P.E., Chief
Construction Grants and Loans Section
March 9, 2009
SUBJECT:
Dear Mr. Brown:
Sincerely,
MWL.dr
Attachment
cc:
___
Enclosed you will find the Determination of Minor Construction Activity (DMCA) for the subject
Engineering Report for Roanoke Rapids Wastewater Treatment Plant. This determination shall become effective
upon its publication in a local newspaper of general circulation by the Roanoke Rapids Sanitary District, and can be
revoked at any time adverse information is made available. The documentation to support this decision should be
kept on file by the Roanoke Rapids Sanitary District and be made available for public viewing, upon request. After
the DMCA has been properly advertised, please furnish this office with a copy of the Affidavit of Publication
certifying the date it appeared, along with a copy of the advertisement. This Determination of Minor Construction
Activity will take effect upon its publication.
Beverly Eaves Perdue
Governor
Kim H. Colson P.E., Assistant Chief
Construction Grants & Loans Section
Dee Freeman
Secretary
1633 Mail Service Center, Raleigh, North Carolina 27699-1633
Location. 2728 Capital Blvd Raleigh, North Carolina 27604
Phone [phone] ', FAX [phone] \ Customer Sennce. 1-877-623-6748
Internet wm ncwaterquality org
An Equal Opportunity' .Affirmative Action Employer
ARCADIS, Miranda W. Spencer, P.E.
DWQ Raleigh Regional Office
Kim Colson, P.E.
Jennifer Haynie, FEU Supervisor
FEU/SRF
NCDENR
North Carolina Department of Environment and Natural Resources
Division of Water Quality
Coleen H. Sullins
Director
Engineering Report For
Roanoke Rapids Sanitary District
Roanoke Rapids Wastewater Treatment Plant:
Sodium Hypochlorite System
DMCA
Project No. CS 370449-04
If you have any questions concerning this matter, please contact Michael Leggett at [phone] or me
at [phone].
Mr. R. Danieley Brown, P.E. - Chief Executive Officer
Roanoke Rapids Sanitary District
P.O. Box 27870
Roanoke Rapids, North Carolina 27870
NorthCarolina
Naturally
Determination of Minor Construction Activity
9
Daniel M. Blaisdell, P.E., Chief
Construction Grants and Loans Section
Division of Water Quality
Project Description: The Roanoke Rapids Sanitary District (RRSD) operates an 8.34 million
gallon per day (mgd) wastewater treatment plant (WWTP) serving the City of Roanoke Rapids,
Town of Gaston, and portions of Halifax and Northhampton Counties. The plant was originally
constructed in 1963 and has been expanded over time to its current capacity. The Roanoke
Rapids Sanitary District has decided to change disinfection systems in order to eliminate the
potential health hazards inherent with chlorine gas and sulfur dioxide gas. This project will
replace the existing gas chlorine disinfection system and dechlorination system at the Roanoke
Rapids WWTP with a new' Sodium Hypochlorite liquid feed system and a Sodium Bisulphite
dechlorination system. New construction associated with the proposed project will include two
bulk storage tanks and chemical feed pumps for liquid sodium hypochlorite, to be housed in a
concrete secondary containment structure enclosed by a pre-engineered steel building, and a
chemical truck spill containment vault. Chemical feed components will be designed for a peak
flow of 20.85 mgd (2.5 peaking factor), while storage units will be designed for the current plant
capacity of 8.34 mgd.
The above named applicant intends to apply for assistance from the State Revolving Fund
program to construct the wastewater facilities described above. The North Carolina Division of
Water Quality (DWQ) has conducted a review of the project in accordance with the procedures
(NCAC 15A Subchapter 1C) for conformance with the North Carolina Environmental Policy Act.
The DWQ has determined that this project is a minor construction activity, and that the
preparation of additional environmental documents is not required.
This determination shall become effective upon its distribution by DWQ and a one-time
publication of this determination by the applicant in a new spaper having local circulation. This
determination can be revoked at any time adverse information is made available. 1 he
documentation to support this decision will be on file with the North Carolina Department of
Environment and Natural Resources, Division of Water Quality, Construction Grants and Loans
Section, and is available for public scrutiny upon request.
North Carolina Division of Water Quality
Construction Grants and Loans Section
Roanoke Rapids Sanitary' District
March 6, 2009
CS 370449-04
$1,229,000
$1,200,000
A
Comments concerning this decision may be addressed to Ms. Jennifer Haynie, Facility Evaluation
Unit, Construction Grants and Loans Section, Division of Water Quality, 1633 Mail Service
Center, Raleigh, North Carolina 27699, or she can be reached by phone at [phone].
Sincerely.
Project Applicant:
Date:
Project Number:
Estimated Project Cost:
Estimated Funding Amount:
PERFORMANCE ANNUAL REPORT 2008
ROANOKE RAPIDS SANITARY DISTRICT
GENERAL INFORMATIONI.
B. Responsible entity: Roanoke Rapids Sanitary District, Dan Brown, CEO
Person in charge/contactC.
MAR - 3 2009
D. Applicable Permit(s)
E. Description of C.S.:
I
I
DENR WATER QUALITY
POINT SOURCE BRANCH
A. Regulated entity: Roanoke Rapids Sanitary District, Collection Systems (C.S.) and
Wastewater Treatment Plant (WWTP)
The system has six sewer lift stations. Three stations are located in the Gaston, NC system.
One of these serves a Northampton County School and one serves the Chowan Housing
Projects and the other station pumps all flows from Northampton County across the NC 48
Bridge crossing the Roanoke River to the Roanoke River Interceptor. The remaining three
pump stations are located within the Roanoke Rapids system. Two of the stations, Belmont
The Roanoke River Interceptor collects wastewater from basins located on the north side of
Roanoke Rapids. The Gaston and Northampton basins are included in this service area. The
Interceptor begins just west of NC 48 in Roanoke Rapids. There are three primary basin
pump stations and one secondary pump station along the route. Pipe sizes for the Interceptor
ranges from 18” to 30”.
The Chockoyotte Creek Interceptor handles the south side of Roanoke Rapids and three sub­
divisions, Lake View Park, Greenbriar and Lincoln Heights, outside the Roanoke Rapids city
limits. The Interceptor begins east of Zoo Road. There is one primary basin pump station
along the route. Pipe size ranges from 12” to 30”.
The collection system consists of approximately 130 miles of sewer lines. The sewer lines
within Roanoke Rapids, Gaston and all sub-divisions, which connect to the two main
Interceptors, range in size from 8” to 12”. There are two main Interceptors transporting
waste to the WWTP.
2. WWTP: NPDES NC0024201
Land Application (L.A.): WQ0001989
Stormwater (General): NCG110000
2. WWTP: Gregg Camp, Operator in Responsible Charge (ORC)
Roanoke Rapids Sanitary District, WWTP
135 Aqueduct Road
Weldon, NC 27890
Phone: [phone]
1. C.S.: Charles Turner, Operator in Responsible Charge (ORC)
Roanoke Rapids Sanitary District
PO Box 308
Roanoke Rapids, NC 27870
Phone: [phone]
1. C.S.: North Carolina Environmental Management Commission System-wide
Wastewater Collection System Permit No. WQCS00027
PERFORMANCEII.
and Poplar Springs, discharge to the Roanoke River Interceptor while the Greenbriar Pump
Station discharges to the Chockyotte Creek Outfall.
F. Description of WWTP:
The wastewater treatment plant is rated at 8.34 million gallons per day (MGD). Peak flow is
rated at 12.5 MGD.
A. Description of overall 12 month performance, noting highlights and deficiencies:
Treatment processes at the wastewater plant include grit and rag removal. This is followed by
primary clarification, trickling filter biological secondary treatment, activated solids
treatment, secondary clarification, final effluent chlorination/dechlorination processes, and
final pH adjustment.
During these processes solids are removed from two locations. Primary clarification removes
settleable solids from incoming wastewater to an anaerobic digestion unit. Here the solids, in
the absence of oxygen, receive pH adjustment, mixing, and heating to produce a stabilized
material. Once the solids are stable, excess water is decanted and returned to the plant for
further treatment. The stabilized, thickened solids are treated with lime for odor control then
removed to a holding tank to await land application.
Secondary clarification removes solids from the activated solids process. Here, solids in the
presence of oxygen, ph control, and mixing, accumulate in excess. They are removed,
chemically stabilized, and added to a holding facility. All stabilized solids are analyzed and
land applied according to their nutrient value, ceiling and accumulative requirements.
There are two pumping stations in the wastewater plant distributing wastewater into and
through the plant. Of these two pump stations, one has the capacity to pump 20 MGD and die
other 27 MGD respectively. Also, to aid these two pump stations; a storm water pump station
has been installed. This station intercepts rainwater, an unnecessary load to the treatment
plant, and removes it before entry to the plant. It has the capacity to pump 11.5 MGD. In
conjunction to these two pump stations there is one pump station with capacity of 21 MGD to
remove treated flows from the plant in the event of high river levels preventing normal gravity
flow discharge. Various others pumps and mixers are located throughout the plant for process
control.
1. C.S.:
The Roanoke Rapids Sanitary District’s collection system received its inaugural permit in
2001 under the North Carolina Environmental Management Commission Department of
Environment and Natural Resources system wide wastewater collection system­
permitting program.
The performance of the system in 2008 was good.
The Fat, Oil and Grease (FOG) program initiated in 1995 has been a good tool in
preventing Sanitary Sewer Overflows (SSO’s). We also have a fulltime employee for the
FOG Program to inspect all records and grease traps. He also educates all restaurants
about grease and how it affects our sewer lines. The use of local newspaper for FOG
program educational ads and the distribution of brochures to restaurants and fast food
businesses have also been effective. Inspection of records and grease traps is an ongoing
measure to prevent SSO’s.
Preventive Maintenance of at least four hours a week cleaning sewer mains has also been
a good tool in reducing sewer backups. The use of degreasers in pump stations on a
regular schedule has proven to be very effective in preventing lift station down time.
Also all pumping stations are checked and cleaned a minimum of twice weekly. '
-2-
The SCADA system that monitors all lift station 24 hours a day, 365 days a year has
prevented lift station overflows.
The yearly average for TSS was 18.9mg/l and CBOD was 4.3mg/l.
average influent values for the same parameters this calculates to a 9'
removal rate respectively. The permit requirement is 85%.
The permit also contains daily maximum residual chlorine of 50 (ug/1) micrograms per
liter. This limit was 28 micrograms in the original permit. However, problems with
analytical testing procedures detecting to 28 necessitated the state to revise the lower
limit to 50. There is also a minimum and maximum pH limit of 6 to 9.
Current plant capacity is 8.34 million gallons per day (MGD) with a peak flow of 12.5
MGD. For 2008 the yearly average low flow was 3.1 MGD with minimum of 2.7MGD.
The yearly average high flow was 6.4MGD with a maximum of 13.9MGD. The yearly
average total flow was 4.0MGD or 48% of the plant capacity. This is a 10% increase
over the previous year.
The increase in 2008 flow can mostly be attributed to resumption of near normal rainfall
from the drought experienced in 2007. Rainfall can contribute to inflow and infiltration
(l&I) thus causing increases in flow.
The District is keenly aware of and has been very responsive to increasing environmental
awareness. House Bill 1160, Clean Water Act of 1999, ratified by the North Carolina
General Assembly on July 20th and signed into law July 21s* by the governor, has
heightened this awareness. This bill codified as Chapter 329 session laws became
effective October 1999.
In response the District has maintained staff, critical parts inventory, equipment
inventory, made plans to better address extreme conditions, upgraded critical equipment,
planned back up or alternative operations, and requested better responsiveness from sub­
contractors. Responses are continuous and increasing.
In 2008, the District continued to be very active in maintenance issues and concerns. The
WWTP’spent in excess of $967,000 on maintenance and repairs to equipment, supplies
and materials necessary to operate equipment and capitalized monies to replace and
upgrade equipment.
Some of the repairs and upgrades in 2008 include the following.
Rag conveyor. The rag conveyor moves debris to a dumpster which is collected by a rag
remover. This debris is removed at this location to prevent downstream line blockages or
clogged pumps and mixers. A gearbox, previously replaced, developed an oil leak. To
prevent premature failure of the gearbox, the gasket seals had to be repaired.
Grit collector. The grit collector removes grit from the influent flow. Grit is removed at
this location to prevent excessive wear on downstream equipment. The main gear on the
drive that settles out grit was severely worn and had to be replaced. In addition, the
pump that removes the settled grit was replaced. The replacement pump used was a
heavy duty pump. As well as priming better, the style of pump used is a chopping pump.
In the event some rags are present at this stage of treatment, this pump will grind and
-3-
2. WWTP:
Overall performance for 2008 was good. There were no NPDES permit limits violations.
(See below) There were no monitoring or reporting violations.
Under the current permit, the District has a weekly effluent total suspended solids (TSS)
limit of 45 mg/1 and a monthly limit of 30 mg/1. Also a weekly carbonaceous
biochemical oxygen demand (CBOD) limit of 37.5 mg/1 and a monthly limit of 25 mg/1.
- ■ . - « Using yearly
92.2% and 97.8%
replaced to return the unit to
-4-
remove the rag as well. To fit this pump into place, the discharge piping had to be
changed out. Previously carbon steel was used. To better withstand the harshness of the
environment at this location, the new discharge pipe used is stainless steel.
Influent pump station. The influent pump station transfers all incoming flow into the
plant. The station is equipped with four pumps. Their pumping capacities are 2, 4, 7, and
7 million gallons per day (MGD). The 2 and 4 MGD pumps are the “work horses” of this
pump station. They handle the majority of the work on normal flow days. This spares
wear and tear on the larger 7 MGD pumps which are needed in cases of higher flows.
They alternate based on run time hours until flows increase to a level where both are
needed together. Since these 7MGD pumps only run for high flows, they do not run
regularly. To ensure proper operation when needed, these pumps are exercised regularly,
v During the exercising of one of these pumps, improper pump operation was observed.
The pump was taken off-line and repaired. The pump has now been restored to service.
Primary Clarifier. The plant has two primary clarifiers, both of which are original pieces
of equipment put on line in 1963. Their purpose is to settle out solids in the incoming
flow. The solids are removed for additional treatment by another process. There is a
surface skimming mechanism also driven by the base support. It collects floatable solids,
mainly grease, and deposits it into a collection pit. The support system between the base
support and skimming mechanism failed causing extensive damage of the support system
and skimming mechanism. All of this metal work had to be fabricated since parts for
these pieces of equipment are no longer available. To access these parts for repair, the
primary had to be drained. While the primary was drained, two isolation valves,
normally submerged, were exposed. Advantage of this situation was taken and the valves
were taken apart and cleaned. They have now been restored for future use and are now
exercised to maintain in operable condition. Also, the gearbox motor that drives the
skimming mechanism and base support failed. It was i ,
service.
Filter Effluent Pump Station. The filter Effluent Pump Station (FEPS) collects all
incoming flow that has traveled through the primary clarifiers and trickling filters. It then
transfers this water on to the secondary system for further treatment. This station is
equipped with four pumps. Their pumping capacities are 2.1, 7.9, 7.9, and 9.2 million
gallons per day (MGD). Here as with the influent pump station, the smaller pump is the
“workhorse”. At this station the two 7.9 MGD pumps alternate after equal run times to
aid the 2.1 MGD pump during normal flows. The 9.2 MGD pump is the high flow pump
at this station. During recent years, the motor control center along with the pump
controlling system was completely replaced. During use, observation, and some repairs,
it was discovered that there were some design flaws in the electronic pump control
system. The flaws could lead to serious failure of the system, resulting in a spill. The
designer, after investigation of this suspicion, agreed there were design flaws. The
designer subcontracted an electronics contractor to redesign and install new components
to correct the problems. Since this was agreed to be a design issue, there was no
additional cost. The problems were corrected and excess of $30,000 was not incurred by
the District. The electronic pump control system of this pump station is protected by
an electrical surge protection device. The device was damaged from a surge but
protected the control system. The protection device has been replaced.
Secondary System. The Secondary System is a biological treatment system consisting of
three aeration basins and two secondary clarifiers. The system is operated by the use of
Recirculation Pump Station. The Recirculation Pump Station (RPS) has three pumps,
each capable of pumping 3 million gallons per day. With the use of these pumps as
dictated by operation conditions, water can be recycled through treatment processes for
additional treatment. One of these pumps started leaking water from around the shaft.
This is a sure sign of internal parts wear and the sooner removed from service the more
expensive repairs can be avoided. The pump was removed from service, repaired, and
returned to use.
-5-
various valves and piping, control panels, traveling siphon bridges with skimmer arms,
gear boxes, motor and pumps, and blowers. Various repairs and upgrades were done.
The gearbox that drives siphoning/skimming mechanism of one of the secondary
clarifiers wore out and had to be rebuilt. Associated with the gearbox are cable pulleys at
each end of the clarifiers. A large pulley on the drive end of the clarifier and a smaller
pulley on the return end. The return pulley on one of the clarifiers failed. This has been
a repair more common than in other areas of this system. In an attempt to change this,
one of these return pulleys was taken to a local fabrication shop. Improvement ideas
were discussed and the wheel was retrofitted with a large more durable center bearing.
The control panel which operates the gearbox has a computer pic operating process. One
of the clarifier computers pic’s malfunctioned and was replaced. The control panels also
have speed control frequency drives. The traveling bridge speed can be adjusted
according to operating conditions. Both control panels had to have drives replaced.
Blowers are used to supply air to the aeration basins for the treatment process. There are
four blowers, two 75 horsepower and two 100 horsepower. Their use is dependent on the
oxygen demands of the aeration basins. One of the 75 horsepower blower’s mtemal
components failed. This is a major failure. The failed blower was sent off for repair^
Once returned, the blower was put back on line. The blowers were fitted with sort
starts”. This equipment is used to reduce torque on the blowers during start up. It will
help reduce the frequency of repairs. Also, by starting the blowers at a slower rate less
electricity is consumed. The blowers are located in a room that makes it difficult to
remove the blower or blower when repairs are necessary. And the room is full, nJaklJ’S
some repairs that do not require removal of the equipment also awkward. To remedy this
situation, a crane lift system was installed. Now removal of the equipment for any
repairs can be done relatively easy.
Disinfection. The final phase of the water treatment process is disinfection (pathogen
kill) and disinfection removal. The former is done with the use of chlorme. The latter is
done to remove residual chlorine because of its negative effect on stream aquatic lite
The chemical used to remove chlorine is sulfur dioxide. The chemicals are injected with
eductor pumps. These pumps are used to create a vacuum on the chemical storage tanks
and to disperse them in a manner which ensures a complete mix of wastewater and
chemical. The chlorine eductor pump failed and had to be replaced with a spare
Technology advancements have produced safer chemical alternatives for disinfection and
disinfection removal. Chlorine can be replaced with sodium hypochlorite and sulfur
dioxide can be replaced with sodium bisulfate. Plans have been completed for switching
to these for safer chemicals. They have been submitted to the State of North Carolina
DWQ for approval and funding. Because of the switch, eductor pumps now used for
iniecting chlorine and sulfur dioxide will not be utilized. Eductor pumps or pump repairs
are expensive. Therefore repairing or replacing them at this time would not be
economically prudent. However, without spares, the plant is at nsk of penmt vidations
if the on-line eductors fail. After some research, a substitute pump for only the fraction
of the cost of an eductor pump could be modified for chemical injection. It is not as
heavy duty as an educator pump and the useful life not as long but injects chemical just
as well. This will prevent a permit violation in the event of an eductor failure before the
system switch. Both chlorine and sulfur dioxide has this set up.
pH meters are located at the beginning, middle, and end of the plant. They are used to
indicate wastewater conditions, monitor plant processes, and prevent permit violations.
The existing meters were getting difficult to maintain and reliability undependable.
There are 3 new meters in place for accurate pH measurements.
Primary Sludge Pump Station. The purpose of the Primary Sludge Pump Station (PSPS)
is to remove settled solids from the primary clarifier and skimmed surface solids
collected in the scum pit. The station is equipped with two pumps to achieve this The
solids are sent to digester stabilization process. The amount of solids pumped to the
digesters needs to be known for process control. For accurate measurement an m-line
magnetic flow measurement meter was installed.
Digesters and Stabilization. Digesters receive solids removed from primary clarifiers.
With heat and mixing and occasional chemical addition for pH control, solids are
stabilized. The heat system is a boiler heat exchanger. Part of the heat exchangers proper
operation involves internally re-circulated heater water. This is accomplished with a
water pump. One of the pumps failed and had to be replaced. The digester building has a
basement. The basement contains several pumps and motors and other process control
equipment. The basement collects water from internal processes, wash-down for clean
up and groundwater seepage. To protect this equipment from water damage, the building
contains a sump pump. The sump pump controller was upgraded to provide more
reliable control of the sump pump. The control is equipped with local alarms in the
building and remote alarms for the SC ADA monitoring system. On-of the pumps located
in the building is used to recirculate solids through the heater. It was replaced with an
upgraded style to be more dependable and efficient. A byproduct of solids stabilization is
methane gas. This gas is captured and is used to heat the heat exchangers. Using this
byproduct saves money on fuel costs. Only one of the two heat exchangers a§ equipped
to take advantage of this. The second heat exchanger has now been equipped to use the
methane as well. The control cabinet was re-wired. A new burner head and mounting
plate were installed. A mounting rack as constructed for the new valves and valve
controllers. And a new exhaust vent stack of proper configuration had to be built and
installed. Now both heaters can maximize the use of methane. Cleaning of the digester
is necessary to maintain proper operation. This is done on a 7-10 year cycle. It also
provides an opportunity for repairs that can not be done while in operation. Digester one
was taken off-line and cleaned. While down, a pearth unit was installed. The pearth uses
the methane available to mix the digester. This enhances digester operation and liberates
additional gas that can be utilized by the heaters. The pearths have tubes or lances that
extend down into the digester area where mixing needs to be done. The gas used by the
pearth passes through the lances into the mixing zone. There are six lances spaced
equally about the digester. All were replaced with the installation of the pearth. Another
byproduct of the solids stabilization process is water. This water needs to be removed to
provide space for additional solids addition to the digester. Removal of the water is
accomplished with a centrally located selector pipe. The pipe is slotted for water removal
and to prevent solids removal. The selector pipe had deteriorated from years of use and
was replaced. The digester building is equipped with many valves. They aid in the
ability to move solids through the building and out. Several were in disrepair and needed
to be replaced. While the digester was empty, the only opportunity to remove these
valves without releasing solids into the building was done. The digester building
contained wiring from the early 1960’s. It was beginning to break down and cause
problems. In an attempt to prevent problems, the entire building was re-wired. This was
a safety issue as well. The digester building was also the area of emphasis for SCADA
additions. Numerous amounts for process control information are now available to
maintain proper operation of the digestion process.
Biosolids Thickening. Excess solids from the secondary treatment process are thickened
by gravity settling tank and a drum concentrator with the use of polymers. Polymers
create a reaction which causes solids to concentrate (floc) and water separate. The
purpose is to minimize the solids removed from the treatment plant because removal
charges are based on the amount of gallons removed. The drum concentrator uses porous
fabric with polymer in the concentrator to thicken solids and porous fabric on the solids
removal conveyor for water removal. The concentrator is mounted to a frame supported
by pillar block bearings, 16 in total. Some of the bearings had to be replaced to insure
operation. The concentrator works off a variable frequency drive. The drive failed and
had to be replaced to continue operation. Polymer use is vital to solids thickening. It is
received in concentrate form and pumped to a bulk storage tank. As needed, it is pumped
to an operations day tank and diluted for use. Seeing the level of available polymer for
use is difficult. To help in knowing volume available, an electronic measuring device
was installed. Water is important to the solids thickening process. It is used to dilute the
concentrated polymer to correct concentration for the thickening reaction. Water is also
used by the drum concentrator to keep the fabrics used for dewatering the solids clean. In
its use, water has to pass through some small valves and orifices. To ensure passage
-6-
-7-
SCADA (Supervisor Control and Data Acquisition) system work. SCADA is a
computer-based program. It brings site information into the central operations center.
SCADA is a useful tool by providing monitoring information to be used for more
efficient plant operation. It also brings remote site alarms into the operations center,
which provides better control over plant problems.
SCADA work continued in 2008. The area of emphasis was the anaerobic digestion
process. Various tank level indicators, process temperatures and pump on-off-tripped
status. In all, 85 indicator signals were added to the SCADA information system. From
these 85 signals, 11 trend charts were developed containing 29 graphed signals. Also 15
alarms were added to help protect building equipment, processes and employees. In
addition, the remote station that sends solids to the digestion process had some signals
added on the SCADA system. Now volume in gallons pumped to the digesters can be
monitored as well as there intervals. However, before any of this information could be
added the SCADA software had to be upgraded. Each piece of information added to
SCADA uses a bit or tag of space. The software originally used had maxed out on its
available amount of tags. Now software is installed that has unlimited tags which will
allow for continues growth of the SCADA information system.
12” pump installation. The 12 inch pump installed at the head-works of the plant in 2000
remains a valuable tool in preventing spills. In the event of high flows or maintenance
repairs, water can be removed to two abandoned secondary clarifiers. These clarifiers
through these areas, a filtration unit was installed ahead of theses devices. Once diluted,
polymer has to be blended in with the solids for proper contact and maximum use. This
is accomplished with an in-line static mixer. The mixer in use deteriorated over time and
was replaced with a new one. After thickening has been achieved, the solids have to be
transferred to the next treatment process. This is done using a positive displacement
pump. This year the pump wore out and had to be replaced with a new one.
Lime Stabilization. Thickened solids are stabilized through the use of lime. Time and
pH’s dictate the stabilization requirement. Lime is received in dry form and transferred
to a storage/feed silo. The dry lime is then fed to a preparation tank. The feed of lime is
done with vibrators that are run for a pre-determined amount of time with the use of an
automatic timer. The timer stopped functioning properly and had to be replaced. Water is
added and mixed with a paddle type mixer. The gearbox that mixes the lime slurry
striped gears and the gearbox had to be replaced. After dilution and mixing, the slurry is
gravity feed to a holding tank containing the thickened solids. There the slurry is mixed
into the solids to equally dispense the lime and to keep it in contact with the solids.
There are two of these holding tanks with a mixer in each. The cord on one of these
mixers was damaged. It was sent off and replaced. The mixer is back on line.
Solids Storage. Biosolids once stabilized are blended and stored in a tank capable of
holding one million gallons. The solids are held and mixed by 3 mixers in this tank to
prevent settling until removed for disposal. Even with mixing, over time settlement
inevitably occurs and approximately once a year needs cleaning. The tank was cleaned to
remove this settlement. Cleaning also allows for the tank to be inspected for integrity. It
also allows for access to the mixers for preventative maintenance. While accessible, one
mixer that had failed was removed and sent of for repair. Stored biosolids are removed
from this tank with a pump into tanker trucks then hauled for land application. During
the year, the pump motor failed and was replaced. Another means of solids storage are
drying beds. This method storage was the original method. It is now a backup and used
only in emergencies due to the difficulty in removing solids for land application. The
storage area is maintained in a ready state in case of need. Te drying beds have an
underdrain system for biosolids water removal and rain. The water flows to an adjacent
pump station where it is pumped back into the plant. The station is 26 years old and the
electrical control panel was in disrepair. A new panel has been built and should provide
long term service. More dependable components were used and placed in a stainless
enclosure versus carbon steel.
/
were taken off-line in the early eighties after plant upgrades. They were originally used
for stabilized biosolids storage. The capacity was increased by extending a wall up from
where the weir overflows were when used as secondary clarifiers. This increased the
storage capacity of the two tanks to 750,000 gallons. After a dedicated biosolids tank
was constructed, the two abandoned tanks were dedicated to spill containment. Once
stored, wastewater can be returned to the plant with an existing pump station. Some pipe
work has been added to this station and depending on conditions, water could be returned
as the tanks are filled. This further increases holding capacity or downtime, during high
flows or maintenance and repairs. In 2008, 2,818,119 gallons of wastewater were stored.
Since setup in 2000, 36,368,552 gallons of wastewater have been prevented from spilling.
At the average flow of 4.0 MGD in 2008, this would be 9.1 days of flow.
The wastewater plant is also equipped with 3 emergency flood pumps. These pumps are
used in the event of high river levels, which prevent normal gravity flow out of the plant.
Two pumps are rated at a pumping capacity of approximately 8 MGD and the third 5
MGD for a total of nearly 21 MGD. Without them, treated wastewater would have no
way of exiting the plant and consequently would flood the plant, causing extensive
damage and long recovery. These pumps are maintained and exercised on a regular basis
to ensure proper operation for times of urgency. It was during one of these exercises that
one of the 8 MGD pumps was beginning to fail. An indicator light showed a seal fail.
-8-
Another means of spill control is with a back-up generator. The wastewater plant must
continue to run in the event of power interruptions from the power-supply company.
Power interruption can occur from equipment failure, road accidents, and weather events,
such as ice storms, electrical storms, tornadoes, and hurricanes. A 750 kilo-watt
generator is on site for events and can supply enough generated power to run the entire
plant. In 2008 power supply was interrupted on two occasions for approximately 7 hours
and 30 minutes. With the use of the back-up generator power 1,328,442 gallons of
wastewater was prevented from spilling into the Roanoke River. This along with the
wastewater stored in equalization tank from maintenance activities and high flows is
37,696,994 gallons. Again, at the average 2008 daily flow of 4.0 MGD this would be
nearly 9 and one half days.
The emergency generator is also used to curtail. The District is under contract with
Dominion Power. From May 16th through September 30th (summer curtailment) and
from December 1st through March 31st (winter curtailment). Dominion can request the
wastewater plant to supply its own power for parts of the day during peak demand.
These requests usually come on the hottest days of summer and the coldest days of
winter. Dominion can then send power that the District would normally use to other
places of need. Winter requests are usually from 6am to 11am (5 hours) but can be 5pm
to 10pm also possibly on the same day. However, each request^ counts as one run.
Summer requests are from 2pm to 9pm (7 hours). The contract is limited. In the winter
requests to curtail are limited to 13 or 65 hours and summer 19 or 133 hours. In 2008 the
wastewater plant was called to run all 19 times during the summer curtailment. There
was one winter call. The District does incur the cost of diesel fuel. However, the rate
structure the wastewater plant has because of the contract off sets this cost and provides
electrical energy savings. An added benefit of this program is that it provides a means to
exercise the generator. This keeps the generator in better running condition and exposes
any potential problem. It would be better to find out a problem during a curtailment than
an actual power outage. By having the generator under a contracted quarterly preventive
maintenance program hopefully problems will be minimized or eliminated. During
contracted preventive maintenance, it was discovered that the voltage regulator was
drifting out of range too far. This made switching off and on regular power difficult.
The regulator was replaced, returning the switch back to normal. Another repair to the
generator was the exhaust muffler. Due to the excess heat produced by the generator,
paint will not stay on the muffler. After approximately 12 years of service, it was just
before developing cracks and holes. A new muffler was installed. However, this muffler
was made from stainless steel. This eliminated the need to try and paint it for protection.
The stainless muffler should provide many years of service.
-9-
The pump was taken out of service and sent off for bearing and seal repairs. Prompt
removal saved the pump from further damage such as motor failure thus decreasing the
amount of money spent on repairs. The pump has been returned to service. This station is
also equipped with local and remote SCADA high level alarms. These alarms provide
notification in the event of station failure. Enough notification time is allowed to take
remedial action before plant damage occurs. The alarms are checked on a regular basis
as well.
This flood pump station has a back-up pump valving and pipe work installed independent
of this station. In the event of catastrophic flood pump or flood pump control panel
failure; treated water will continue to be removed from the plant. The pump is capable of
treating 8.5 million gallons per day or about 4.5 million gallons more than the average
daily flow in 2008. Plant maximum rated capacity is 8.3 million gallons per day. The
pump was covered to help keep it protected and in better working condition. Lighting
was provided for nighttime operation. Also, a battery charger was installed to keep the
pump ready for use. The pump is exercised regularly to ensure performance.
The biosolids land application program permitted by the Environmental Protection
Agency (EPA) ran well in 2008. In the required annual report to North Carolina division
of Water Quality (NCDWQ) and the (EPA), there were no deficiencies or spills. In 2008
there were 201 lime stabilization events at 12750 gallons per event for a total of
2,741,250 galloons. This is 59 % of the days in a year. The anaerobic digestion process
produced an additional 425,000 gallons of stabilized solids. Although these solids have
met all requirements for stabilization, they are also limed. This is done solely for the
purpose of odor control. The wastewater plant has entered into agreement with area
farmers for the use of their land for biosolids application. The farmers in turn receive the
nutrient value, moisture content, soil remediation, and lime, which is a by-product of ph
control in the treatment process of the biosolids. If necessary, additional lime can be
applied. There are 3100 acres, consisting of 128 fields, available in Halifax,
Northampton, and Warren Counties. All acreage was inspected, approved, and permitted
by the State of North Carolina. Using EPA approved treatment processes, 3,081,000
gallons of stabilized biosolids were safely applied to area lands, consisting of 4 fields and
190 acres, for beneficial reuse. This included the use of three different farms. Cost of
this application process was approximately $76,000. Cost of treatment to stabilize solids
is separate. Land that grew fescue, rye, and bermuda were applied to. The amount
applied in 2008 is up nearly 11 % from the previous year. Charges for application are
based on gallons. In an attempt to save application costs, biosolids are thickened as much
as can possibly be handled. The removed water is returned to the treatment plant. Also,
once biosolids are placed in storage for land application, water is further separated. This
water along with environmental water (rain, snow, etc) is decanted and returned to the
treatment plant. In 2008, 460,000 gallons was decanted, at savings of $14,280. Although
3100 acres of land is permitted and storage of 1,000,000 gallons is available, at times
application is difficult due to weather conditions, crop status, and crop rotation. Owning
land would provide an outlet for these times. In 2004, the District purchased a suitable
land application site. It is located in Northampton County where the District already has
farmer owned land permitted. The land has been developed for livestock (cow)
operation. The area has been split into two fields. One contains 41.8 acres of fescue and
the other contains 67.2 acres of bermuda. Both fields received application of biosolids in
2008. Fescue was applied 1,337,500 gallons which is approximately 32,000 gallons per
acre. Environmental Protection Agency (EPA) regulations allow up to 15% more per
acre on fescue (as determined by nitrogen and % solids content). Bermuda was applied
1,033,000 gallons which is approximately 15,300 gallons per acre. EPA regulations
allow up to 3 times more per acre on Bermuda (as determined by nitrogen and % solids
content). Both grasses responded well to the applications. The fields were intentionally
split into these two types of grasses too provide for winter and summer applications.
Also this allows the cows to be moved off the field (the two fields are separated by fence)
which has been applied to for the EPA regulated 30 days.
weed killer and
Since purchasing the land, investment improvements continued in 2008. Improvements
have been going on for nearly five years. Therefore, large improvements have been
accomplished and most of the work now is maintenance. There was an old house located
on the site. It was removed for approximately $1000.00. The lessee of the land removed
some dead trees and limbs from the exterior fence, sprayed some weed killer and
installed a catch pen for his cattle.
In 2008 the industrial pretreatment program had oversight of two significant industrial
users. One user has a categorical discharge pipe. Four non-signiflcant industrial users
are permitted to send flow to the wastewater plant. Significant and non-significant status
is determined in part by the volume of flow discharged and the pollutants in the
discharge. The pollutants, carried by certain industrial wastes, determine the categorical
status of an industry. Each industry whether classified as a significant or non-significant
user is issued a permit with limits and monitoring requirements. In 2008 there were no
significant industrial users in significant non-compliance; a status based on the number
and types of violations of a permit. There was one Notice of Non-Compliance sent for
excessive flow.
The pretreatment annual report (PAR) was submitted to the state pretreatment unit on
February 26, 2008. A letter, dated April 23, 2008, was received stating review of the
PAR indicates the report in good order and satisfied the requirements of the North
Carolina Pretreatment Program.
Additional requirements of the program include an annual Environmental Protection
Agency quality assurance study as a requirement of NPDES monitor reporting, state
inspections, quarterly in-house blind studies, maintaining a quality control program and a
chemical hygiene plan, a chemical inventory plan, equipment calibration and
certifications, and certification fee.
- 10-
A revision of the Long Term Monitoring Plan was sent to the Division of Water Quality
Pretreatment, Emergency Response, and Collection Systems Unit for approval on March
31, 2008. After review by the Division and further revision, a final Plan was submitted
on June 2008.
The North Carolina Division of Water Quality performed its five year audit of the
pretreatment program on September 12, 2008. A letter of October 23, 2008 was received
complementing the program on the organization, documentation, and time management
instituted within the program.
The District wastewater plant has an on-site monitoring laboratory. Analysis for NPDES
reporting to the Division of Water Quality must be performed by a certified laboratory.
The laboratory is certified by the North Carolina Division of Water Quality Laboratory
Certification Section. In order to become certified the laboratory facility must meet space
and equipment specifications as well as analysis performance evaluation. The laboratory
is currently certified for twelve inorganic parameters and four Vector Attraction
Reduction options for the treatment of biosolids. The laboratory receives samples from
approximately 39 sampling pints that include plant monitoring, industrial monitoring,
performance evaluation studies, septage hauling, and collection system samples.
The laboratory has two full-time and one part-time technician, a laboratory supervisor,
and laboratory manager. After the laboratory obtains certification, it must complete an
annual performance evaluation study and submit the results to the state certification
section. This performance evaluation must in the form of a “blind” study. Study samples
are ordered from a state approved vendor. The study sample values are unknown to the
laboratory. The samples are analyzed and the results are submitted back to the supplier
fro grading. If the laboratory fails to achieve an acceptable rating on a parameter for
three consecutive samples, the laboratory could loose certification for that parameter. If
certification is lost, the laboratory must go through a recertification process as if they had
never achieved certification.
Each of theseInspections resulted in the issuance of fourteen Notices to Correct,
corrections was made by the receiving restaurant in a timely manner.
The laboratory submitted all required evaluation studies and eceived an acceptable rating
on all in-house study parameters.
The laboratory also works in association with the pretreatment program and biosolids
program in that analysis of samples taken by pretreatment technicians and plant operators
are brought to the laboratory for analysis. A laboratory technician is also responsible for
entry of the resulting data into a spreadsheet that is used by the Pretreatment program for
its Long Term Monitoring Plan. Laboratory technicians are also responsible for data
entry into the plant operations spreadsheet used for NPDES permit compliance
monitoring and plant process control.
The laboratory works in coordination with the state certification branch to certify field
testing equipment for the surrounding communities with small treatment facilities who
work on limited funds. At this time, the laboratory assists six small facilities with
equipment certification.
The FOG ordinance allows for variance in the grease trap cleaning schedules with the
completion of a variance study. In 2008, one variance study was completed that resulted
in the granting of an extended pumping schedule for the restaurant.
Variances are also granted for inability to install an outdoor trap based on space
constraints. Three variances were granted to allow the installation of indoor self-cleaning
traps based on space constraints.
Because of space constraints, two restaurants were accessed surcharges in lieu ot trap
installation. Each restaurant is surcharged to recover the cost of line cleaning and line
maintenance.
There were two sanitary sewer overflows that were attributed to FOG. The overflows
occurred in residential areas. Educational information was dispersed to nearby residents
to inform residents of how they can help prevent FOG accumulation in sewer lines that
lead to overflows. Two blockages also occurred. One blockage was in a residential area
and the other attributed to a restaurant. The residential blockage occurred at a multi­
family housing unit. Informational handouts were given to the residents and the District
began performing more frequent line cleaning in the area. The restaurant has begun
using Best Management Practices to decrease the amount of grease that enters the lines
and began cleaning the trap with greater frequency.
FOG public education is a requirement of the wastewater collections system permit
WQCS00027. Ongoing efforts from 2007 continued in 2008 with the revision of a FOG
slide that airs on local television Channel 15 and the addition of a FOG pamphlet
enclosure with one billing cycle. The administrative staff began distributing a FOG
ordinance package to all new Food Preparation Facilities when opening a new account.
The administrative staff also gives out industrial waste surveys to each person who opens
- 11 -
The Roanoke Rapids Sanitary District adopted its first Fats, Oils and Grease (FOG)
Ordinance in 2005. Since then operational issues under the ordinance arose. In 2008, the
District addressed those in a revision and subsequent adoption of new ordinance
language.
During 2008, there were sixty-five restaurants in the District database. This included the
opening of six new restaurants and the closure of two. Each of the restaurants was
inspected in 2008. Updates to the database information in 2008 include updating
information such as management contact information and new restaurant information.
a commercial account that asks questions regarding food preparation and grease traps.
Best management Practices (BMP) posters were obtained by the District and distributed
to those contributors who have the potential to discharge FOG, but may not require
installation of a grease trap. Examples of these establishments include schools, churches
and daycares. Before accepting flow from a new multi-family housing development,
FOG pamphlets are distributed to residents and the FOG program is discussed with the
management.
A requirement of the wastewater plant through its NPDES permit is quarterly chronic
toxicity testing. The test involves using a predetermined amount of effluent along with a
macroscopic organism. Ceriodaphnia are placed in the effluent and must survive and
reproduce for a specific length of time. Results of the test are either pass or fail. A pass
indicates the absence of substances in the effluent which may be harmful or threaten
aquatic life. The wastewater plant has been required to test for chronic toxicity since
April of 1993. To date only one test has received a fail result. This occuned in July
2001.
Another testing requirement of the NPDES permit is the annual priority pollutant analysis
(APPA). As indicated, it is an annual test that checks the effluent for conventional and
non-conventional compounds, total recoverable metals, volatile organic compounds,
acid-extractable compounds, and base-neutral compounds. These substances, if found in
sufficient quantity, could be harmful to the wastewater plant, receiving stream, and the
public. To date, no substances have been found in significant quantity to cause harm.
The test is done seasonally over the term of a five year NPDES permit.
The wastewater plant now has a general storm water permit. It was received through an
application process as required by the North Carolina Division of Water Quality. A
requirement of this permit is a written storm water management plan. The plan is used to
evaluate potential pollution sources and to select and implement appropriate methods to
prevent or control the discharge of pollutants to stormwater runoff. As a part of the plan,
semiannual preventative maintenance evaluations and semiannual inspections of site
runoff areas are required.
The Division of Water Quality conducted their annual review of the wastewater plant
April 2, 2008. A comprehensive site inspection was conducted. The site inspection went
well. The evaluation report received on April 10, 2008 stated the plant was in
compliance. There were no recommendations or corrections. The report noted that the
plant was well run with all operational units functioning as they should. Noted too was
the sound stormwater program and its implementation. The report also commended the
installation of observation stations.
The safety program within the District is very active and assertive in its approach to the
protection of the employees and surrounding citizens. The program consists of a safety
officer, safety committee, incident/accident committee and appeals committee. The
safety officer sets up the monthly safety meetings, coordinates the activities of the safety
committee, keeps up with safety regulations, and many other various safety activities.
The safety committee prepares safety policy programs and updates current ones. They
also do site inspections and produce potential hazard punch lists. The safety committee
and safety officer also keeps up with and prepares for updating regulations and
integrating new regulations of OSHA. The incident/accident committee reviews all
potential accidents and accidents. The appeal committee follows up the safety committee
recommendation at the request of an employee. The attempt is to minimize the
seriousness of an accident and ultimately prevent accidents. As a result of the awareness
- 12-
The wastewater treatment plant has a National Pollutant Discharge Elimination System
(NPDES) permit. It is issued by the Division of Water Quality (DWQ) after final
approval is granted by the Environmental Protection Agency (EPA). The permit
authorizes discharge of treated wastewater to the
Roanoke River. The current permit is valid through March 2012.
Permit limit violation
Monitoring and Reporting Violations
2008 Sanitary Sewers Overflows (SSO)
1.
Bypass of Treatment Facility
and training from the safety program, there were no loss work days in 2008 at the
wastewater treatment plant.
1.
2.
3.
7/5/08 - M/H 54 at 4th & Laurel St.
7/5/08-M/H 10 at Hall St.
2. WWTP: N/A
B. By month, list of the number and type of any violations of permit conditions,
environmental regulations, or environmental laws, including (but not limited to):
The District has an emergency response team (ERT). Because the wastewater plant is the
only location with chlorine and sulfur dioxide, now, the response van is now located here.
This should help with response time in the event of an emergency. Also relocated to the
plant is the chlorine gas detector. It has been assigned a caretaker who also does monthly
calibrations. The formation of the team arose from chemicals, chlorine, and sulfur
dioxide stored on site. Another factor for its formation was the lack of any other agency
in the immediate area to deal with these chemicals. The team meets and has drill
practices regularly. The team is fully equipped and trained to handle emergencies which
may arise from the use of chlorine and sulfur dioxide.
C.S.: There were 8 reportable SSO in 2008.
2/28/08 - Turn M/H at Southgate Dr.
2/18/08 - 500 Blk. Washington St.
3/7/08 - M/H 54 at 4th & Laurel St.
4. 4/20/08 - Greenbriar Pump station
5. 4/20/08 - M/H 54 Belmont Pump Station
6. 4/21/08 - Kapstone Paper Mill
7.
8.
2. WWTP:
There was one reportable bypass of the treatment facility in which wastewater reached
surface waters in 2008. It occurred on September 26 while one primary clarifier was
down for service. During this down time, the plant experienced some high flows putting
excessive flow into the primary clarifier on line. The line that flows to the primary
overflowed approximately 250 gallons that was spilled. As required, the spill was
reported to the Division of Water Quality (DWQ) within 24 hours by phone and followed
- 13-
1. C.S.: N/A
2. WWTP: None
1. C.S.: 8
2. WWTP: None
1. C.S.: None
C. Description of any known environmental impact of violations.
2.
1 on them. As the pits
be restricted, back up, and
up with a written report within 5 days. Due to the volume of the spill being less than
1000 gallons, no further action was required. A line cleaning crew was brought in to
clean and inspect the line. The primary clarifier has been returned to service. The
affected area of the spill was cleaned and disinfected.
WWTP:
The WWTP is very aggressive in reacting to violations and identifying potential
deficiencies. Once identified, plans are made to upgrade or replace potential deficiencies,
which may result in violation. Modifying operations, training operators, laboratory
training, improved equipment, maintenance inventory parts and equipment and raising
awareness is also an on-going and continuous process.
Some of the work done to prevent problems is the identification of potential spill areas.
Once identified, arrangements are made to stop or minimize and contain.
During a construction project in 2007, influent was diverted to equalization tanks.
During the process it was discovered that a valve was not seated properly and some
spillage occurred. A temporary pipe plug was installed down stream to prevent future
spills. Funding was budgeted the following fiscal year to replace the temporary plug with
a permanent valve.
The wastewater plant uses chlorine for effluent disinfection. It uses sulfur dioxide to
remove the chlorine after disinfection has been accomplished. Both chemicals are very
effective; however, both are also very toxic. In 2008, plans were drawn up for switching
over to safer chemicals. Funding was budgeted and low interest rate loans applied for.
Sodium hypochlorite will replace chlorine and sodium bisulfate will replace sulfur
dioxide. As well as being safer, these chemicals are just as effective.
The grit removal equipment screw shaft bearing failed. It had to be replaced promptly to
prevent the shaft from wearing a hole in the shaft hosing releasing untreated wastewater.
This water could have easily reached receiving waters.
The influent pump station has a local alarm horn and light. It is on a large pole to make it
noticeable through out the plant site. High winds over time damaged the pole and was
threatening the usefulness of the alarm. A new larger diameter pole was installed
restoring the effectiveness of this alarm.
Primary clarifier influent lines have grease collection pits located
collect grease and fill, the flow through the influent lines can I—
- 14-
D. Description of corrective measures taken to address violations or deficiencies.
1. C.S.: None
2. WWTP: None
1. C.S.: .
Preventive maintenance cleaning with Jet Vac, and a rot cutter which is attached to the
Jet Vac hose for cutting roots and using TV camera. Manhole repairs and spot line
repairs. Plus the Roanoke Rapids Sanitary Dist. Crews cleaned & TV’ed 21 miles of
sewer lines. Bionomics inspected M/H’s, TV’ed, and cleaned 4 miles. MJ Price
Construction cut Chockyotte Creek Outfall and Laterals which was 8 miles, making it a
total of 33 miles between all 3 companies. The district had 8 reportable spills in 2008.
Three at 4th & Laurel St., two at Greenbriar Pump Station, one at Kapstone parking lot,
one at 500 blk. of Washington St. and one at Charles Circle. At Southgate Dr. the district
replaced Belmont Pump Station with Smith and Loveless above ground pumps and
replaced the force main with 6 inch PVC pipe. The district also cleaned and TV ed the
main line from Belmont Pump Station to 2nd and Franklin St.
cause spills. To prevent this from occurring, a contracted vacuum truck company is
scheduled regularly to remove the excess grease and keep he lines unrestricted.
There are three pumps in the plant used to re-circulate filtered wastewater. They are
located near storm drains that lead to receiving streams. As these pumps wear, leakage
can begin. One of the pumps began leaking and was removed from service before
spillage could occur. The pump was repaired and restored to service.
Two main pump stations move wastewater through the plant. Both have a primary and
back-up pump controller. Both stations back-up pump controllers consist of a cable/float
system. In the event the primary controller fails, it automatically switches to the backup
controller. On one of these pump stations the cable/float broke. The backup system was
inoperable and had the primary system failed, a spill was possible. The cable/float was
repaired and the backup pump control restored.
Chemicals are used for pathogen reduction and toxic chemicals removal. This process
constantly runs year round. Eductor pumps are used to accomplish feed of the chemicals.
These are submersible pumps that recycle wastewater to create a vacuum which pulls
chemical into the wastewater for treatment. The process requires the use of two eductor
pumps. And with the requirement of constant treatment, two backup pumps were
inventoried. These pumps are in excess of $10,000 with a typical repair costing
approximately half this amount. Two of the pumps are in need of repair and the system
was without backup pumps. The hesitation for the repairs is that this type of system is in
planning stages to be completely changed over and eductor pumps will not be utilized. In
the mean time, there is still a need for backup. After investigation, it was discovered that
an above water pump adapted with a blending unit could accomplish the same results as
an eductor pump. Two backup pumps were installed for less than $1000 or a fraction of
the cost of one eductor pump. And now the chemical feed system has backup feed
pumps thus reducing the likelihood of a permit violation.
Two tanks of 25% liquid caustic, one 300 gallons and the other 1000 gallons, are located
at the effluent of treatment processes. The caustic is used to maintain a pH greater than
the permit limit of 6 when needed.
The 1000 gallon tank developed a slow leak and was emptied and removed from service
before a major leak could result in environmental problems. Due to the low amount of
caustic needed for maintaining pH, a 500 gallon tank was installed to replace the 1000
gallon tank. For the same reason the 300 gallon tank was removed from service as well.
Now with a new tank on-line and storage reduced over 50%, the likelihood of
environmental problems has been largely reduced.
Twenty five percent liquid caustic is located in the basement of the digester building. It
is used on as needed basis to maintain a neutral pH in the anaerobic digesters. The
basement of the digester building is subject to collect water due to groimd water seepage,
equipment and floor wash-down, and eye/shower wash use. For this reason, a water
collection pit equipped with a sump pump is located in the basement. Water collected
here is pumped into the plant treatment processes. This same pit serves as containment in
case of leaks from the caustic tank. However, caustic is high in pH and in large doses
could be harmful to treatment processes. For this reason, a pH probe was installed and
connected into a building alarm and SCADA alarm. In the event of a leak, the amount of
spilled caustic returned to the plant can be controlled, reducing the impact to treatment
processes.
A valve exercise program is now employed. It keeps valves in good working order. In
the event of routine maintenance, equipment problems, or emergencies, valves used to
address these issues are in a state of readiness. Some of the larger valves in the exercise
program can be more difficult to exercise because of the number of turns needed to open
and close the valve. Some may take approximately 200 turns. To make these valves
easier to turn, electric actuators have been installed. Two 24” and two 30” valves were
fitted this year. As valves are repaired or replaced, they are added to the exercise list.
- 15-
III.
IV.
A.
- 17-
7
Date
Reduce
Recycle
Satisfy
Develop
7
R. Danieley Brown, PE
Chief Executive Officer
CERTIFICATION
I certify under penalty of law that this report is complete and accurate to the best of my
knowledge. I further certify that this report has been made available to the users of the
named system and that those users have been notified of its availability.
NOTIFICATION
A. A condensed, summarized version of this report will accompany the annual water report
which will be distributed to the users and customers of the Roanoke Rapids Sanitary
District via mail. The full report will be available at the main office upon request.
In another attempt to minimize or eliminate contamination run off, the waste water plant
now stocks disinfectant. In the event of an on-site spill, the affected area is cleaned and
then sprayed with disinfectant.