NC0024201_Historical information (Inspections)_20101231

November 29, 2010
Deai' Mr. Brown:
GWH/gwh
cc:
The Construction Inspection Group (CIG ) of the Construction Grants and Loans Section
performed an interim inspection for the state and federally funded portion of subject project
at 11:00 am Friday November 19, 2010. Monthly progress meetings until lately were normally
scheduled for the 2nd Friday each month. Location of the Progress meetings is the WWTP located
on Aquaduct Rd. The next scheduled progress meeting and interim inspection in December is to
be determined. For loan and grant purposes the Contract completion date remains Dec. 13, 2010.
You should review this report, take actions or provide responses as indicated and then file
with your project records. If you have any questions please contact me at [phone] or via
e-mail [e-mail] .
Beverly Eaves Perdue
Governor
Subject: Interim Inspection
Roanoke Rapids SD [HALIFAX]
WWTP Sodium Hypochlorite System
Project No. CS 370 449-04
Dee Freeman
Secretary
F \SHAREXProjEct Management BranchXGroup - Construction InspectionXPrDjBcts (Active)\Roanoke Rapids SRF gwh\lnt Insp 10-11-19 RDan.okeRapids.doc
Construction Grants & Loans Section
1633 Mail Service Center Raleigh NC 27699-1633
Phone:[phone] / FAX: [phone] / Internet: http://portal.ncdenr.org
An Equal Opportunity/Affirmative Action Employer
Mr. R. Daniel Brown, PE
Roanoke Rapids Sanitary District
PO Box 308
Roanoke Rapids, North Carolina 27870
Hunter Carson, PE. Arcadis
Danny Smith, Raleigh Regional DWQ Office
SRF
• •
NCDENR
North Carolina Department of Environment and Natural Resources
Division of Water Quality
Coleen H. Sullins
Director
NorthCarolinaNaturally
RECEIVED
NOV 3 fl 1019
NC OENR Raleigh Regional 0«ice
Sincerely. ~ / /
Uy [ J
Gerald W. Horton. PE
Environmental Engineer
Construction Inspection Group
5.
18.
20.
22.
23.
24.
25.
26.
27.
28.
29.
district
ite System
Page 2 of 3
Interim Inspection of
November 19, 2010
Roanoke Rapids Sanita^Ji
WWTP Sodium Hypoc^mi
CS 370 449-04
GENERAL CONCERNS / RECOMMENDATIONS / ACTION ITEMS -Please note UPDATES
on Comments and Concerns noted in previous progress meetings (for reference) are italicized.
Nov. update: Engineer stated bolts installed per manufacturer's instructions. October-
building frame has been erected. Owner questioned bolt pattern and if some were missing
at perlin/column connections. Engineer to check on connections. September -building by
ARCO is scheduled for start of erection on Monday Sept. 13. Erection can finally initiate
now as tanks have been set in place. August - WWS anticipates constructing building in
the next weeks. Pre-Engineered metal building is manufactured by ARCO and will be
installed by Rabon.
Nov. update: engineer stated the O&M manual would be submitted in December.
October-Owner provided Engineer Section 3.13 Disinfection System O&M for Engineer to
revise/update for this project. O&M yet to be submitted to CG&L for approval. September
- nothing yet submitted. IMPORTANT - O&M must be approved by CG&L before
reimbursements beyond 95% will be made. Submit O&M Manual to the attention of
Kavitha Ambikadevi. CG&L advised Owner and Engineer an O&M Manual is required
for the new work and also a closeout checklist should be provided for possible Final
inspection at next meeting. CG&L sent via email: 1) closeout checklist, 2) O&M
preparation guidance document and 3) Owner O&M review form.
Nov. update: Owner has received letter and deems installation and manufacturers
assurances acceptable. October - he faulty lift lugs on the fiberglass tanks were tested
successfully. Owner and Engineer still expecting and insisting on a revised warranty letter
from the tank manufacturer, and revised tank drawings.
Nov. update: Owner has received manufacturer's documentation prepared by P.E. attesting
to proper design. Metal building manufacturer (ARCO) delivered 8 bent and damaged
structural pieces which has delayed WWS. Owner and Engineer still expecting and
insisting on a revised warranty letter from ARCO the building manufacturer.
Nov. update: yet to test piping due to situation with 6 chemical pumps. Testing of chemical
piping and equipment is pending with two days of startup and two separate days of training
and one day of follow-up specified in 6 months after completion.
Nov. update: can't test waterline until sprinkler system is completed. Oct. - Owner is
concerned about potential for leaks in the new 6" waterline. Owner will keep it
pressurized.
CG&L advised Owner and Engineer to contact DWQ regional office to notify them of
startup.
The level gage columns attached to the tanks appear to be mounted in a manner where the
column load is supported only by the fittings. CG&L requests Engineer respond to this
observation.
In the event Engineer conducts final inspection before next meeting, CG&L hereby
requests copy of punch list. A Final Inspection checklist was provided via email.
Work remaining includes but is not limited to: testing chemical feed lines, installation of
sprinkler system, manufacturer's checkout of pumps, miscellaneous training, install Saf-T
diffuser, ref. drwg. C102, punch list walk through, and site work and cleanup.
A Final inspection by CG&L is to be scheduled.
LOAN DISBURSEMENTS
As of November 18 reimbursements for the construction contract totals $806,908, which is
73% draw vs. 92% of time expended. The loan is for max. 20 years at interest rate of 2.5 %.
RFPs Status none pending
RFIs Status - current
Project Schedule - WWS is contemplating finishing in September.
Signage - Project sign has been erected and information for OSHA, wage rates etc. are posted.
SUBMITTAL Status- all submittals have been approved
252 537-9132
Gregg Camp 252 536-4884
Justin Blackmon 252 537-9137
Hunter Carson, PE 919 854-1282
Billy Clinard 919 625-8864
Brandon Clinard
Gerald W. Horton, PE NC Construction Grants & Loans 919 715-6291
Inspectors logs/Work Orders - CG&L requests these be available for review at all meetings.
Inspection is part time and on as needed basis. Inspection logs were reviewed at this and the
October meeting and deemed adequate.
As-builts or Record Drawings - were not reviewed at today's meeting, but were reviewed at
earlier meeting. Please have these available for review at all meetings.
Roanoke Rapids San. Dist., Director
[e-mail]
Roanoke Rapids San. Dist.
[e-mail]
Roanoke Rapids San. Dist., Constr. Obsrv.
[e-mail]
Arcadis
hunter.carson @ aarcadis-us.com
Water & Waste Systems Constr., Inc.,
[e-mail]
Water & Waste Systems Constr., Inc.,
Page 3 of 3
Interim Inspection of
November 19, 2010
Roanoke Rapids Sanit;
WWTP Sodium Hypoc
CS 370 449-04
CONTRACT:
WWTP Sodium Hypochlorite System - Water & Waste Systems Construction, Inc., (WWS)
9700 Ten-Ten Rd., Raleigh, NC 27603
Total
$ 901,000
CHANGE ORDER UPDATE - CG&L stated if Owner wishes to have change orders considered
for funding then they must submit executed change order(s). A change order checklist was
provided earlier via email.
List of Attendees:
Dan Brown, PE
Project budget:
Amount
Water & Waste Systems Constr., Inc.
Contingency
Technical Services_______________
Total Eligible Costs
strict
iclrorite System
Eligible
$ 901,000
$ 45,000
$ 164,800
$ 1,110,800
November 2, 2010
Deai' Mr. Brown:
in'cerely,
GWII/wh
cc:
You should review this report, take actions or provide responses as indicated and then file
with your project records. If you have any questions please contact me at [phone] or via
e-mail [e-mail] .
Beverly Eaves Perdue
Governor
Dee Freeman
Secretary
F \SHARE\Pnj|ect Management BranchXGroup - Construction lnspection\Pro]ects (Active)\RoanoFe Rapids SRF gwhMnt Insp 10-10-08 RuanakeRapids dnc
Construction Grants & Loans Section
1633 Mail Service Center Raleigh NC 27699-1633
Phone:[phone] / FAX: [phone] / Internet: http://portal.ncdenr.org
An Equal Opportunity/Affirmative Action Employer
Mr. R. Daniel Brown, PE
Roanoke Rapids Sanitary District
PO Box 308
Roanoke Rapids, North Carolina 27870
Hunter Carson, PE. Arcadis
Danny Smith, Raleigh Regional DWQ Office
SRF
NCDENR
6-J
Gerald W. Horton, PE
Environmental Engineer
Construction Inspection Group
North CarolinaNaturally
North Carolina Department of Environment and Natural Resources
Division of Water Quality
Coleen H. Sullins
Director
The Construction Inspection Group (CIG) of the Construction Grants and Loans Section
performed an interim inspection for the state and federally funded portion of subject project
at 11:00 am Friday October 8, 2010. Monthly progress meetings are normally scheduled for the
2nd Friday each month. Location of the Progress meetings is the WWTP located on Aquaduct Rd.
The next scheduled progress meeting and interim inspection is Friday October 8, 2010. Contract
completion date remains December 3, 2010.
Subject: Interim Inspection
Roanoke Rapids SD [HALIFAX]
WWTP Sodium Hypochlorite System
Project No. CS 370 449-04
RECEIVED
NOV' 3
NCDENR Rateigti Regional °«»ce
1.
5.
18.
20.
23.
24.
CHANGE ORDER UPDATE - CG&L previously requested Change order #1. Owner and
Engineer are advised - if Owner wishes for items to be eligible for funding, a change order should
be submitted. This is not a guarantee it will be approved by CG&L. The same applies for CO#2
and any subsequent COs. October meeting, CG&L informed there will be a CO#3.
21.
22.
Page 2 of 3
Interim Inspection of
October 8. 2010
CONTRACT:
WWTP Sodium Hypochlorite System - Water & Waste Systems Construction, Inc., (WWS)
9700 Ten-Ten Rd., Raleigh, NC 27603
Roanoke Rapids Sanita,
WWTP Sodium Hypoci
CS 370 449-04
^fcistrict
i^mte System
GENERAL CONCERNS / RECOMMENDATIONS / ACTION ITEMS -Please note UPDATES
on Comments and Concerns noted in previous progress meetings (for reference) are italicized.
October update: a revised schedule was not provided at meeting CG&L requested being
provided the revised schedule in pdf format via email. September -WWS did not provide
update construction schedule at this meeting. CG&L requests the updated schedule be
submitted via email. August - Water & Waste Systems, Inc. (WWS) maintains they will
complete job on time or ahead of time. May - WWS proclaims to be on schedule and will
finish on time if no problems encountered.
October update: building frame has been erected. Owner questioned bolt pattern and if
some were missing at perlin/column connections. Engineer to check on connections.
September -building by ARCO is scheduled for start of erection on Monday Sept. 13.
Erection can finally initiate now as tanks have been set in place. August - WWS
anticipates constructing building in the next weeks. Pre-Engineered metal building is
manufactured by ARCO and will be installed by Rabon.
October update: Owner provided Engineer Section 3.13 Disinfection System O&M for
Engineer to revise/update for this project. O&M yet to be submitted to CG&L for
approval. September - nothing yet submitted. IMPORTANT - O&M must be approved
by CG&L before reimbursements beyond 95% will be made. Submit O&M Manual to the
attention of Kavitha Ambikadevi. CG&L advised Owner and Engineer an O&M Manual is
required for the new work and also a closeout checklist should be provided for possible
Final inspection at next meeting. CG&L sent via email: 1) closeout checklist, 2) O&M
preparation guidance document and 3) Owner O&M review form.
The faulty lift lugs on the fiberglass tanks were tested successfully. Owner and Engineer
still expecting and insisting on a revised warranty letter from the tank manufacturer, and
revised tank drawings.
Door frames and hinge patterns do not match, doors being sent back.
Metal building manufacturer (ARCO) delivered 8 bent and damaged structural pieces
which has delayed WWS. Owner and Engineer still expecting and insisting on a revised
warranty letter from ARCO the building manufacturer.
Testing of chemical piping and equipment is pending with two days of startup and two
separate days of training and one day of follow-up specified in 6 months after completion.
Owner is concerned about potential for leaks in the new 6" waterline. Owner will keep it
pressurized.
LOAN DISBURSEMENTS
As of October 19 reimbursements for the construction contract totals $719,984, 65% vs. 78%
of time expended. The loan is for maximum 20 years at interest rate of 2.5 %.
RFPs Status - none pending
RFIs Status - WWS asked who furnishes chemicals for new tanks
Project Schedule - WWS is contemplating finishing in September.
Signage - Project sign has been erected and information for OSHA, wage rates etc. are posted.
252 537-9132
Justin Blackmon 252 537-9137
Hunter Carson, PE 919 854-1282
Billy Clinard 919 625-8864
Brandon Clinard
Gerald W. Horton, PE 919 715-6219
Inspectors logs/Work Orders - CG&L requests these be available for review at all meetings.
Inspection is part time and on as needed basis. Inspection logs were reviewed at this the October
meeting and deemed adequate.
SUBMITTAL Status- all submittals have been approved, but fiberglass tanks re-submittals are
still outstanding.
|i strict
ite System
Roanoke Rapids San. Disk, Director
[e-mail]
Roanoke Rapids San. Disk, Constr. Obsrv.
j b I ac kmon @ rrsd. org
Water & Waste Systems Constr., Inc.,
bclinard @ wwsys.com
Water & Waste Systems Constr., Inc.,
NC Construction Grants & Loans
gerald.horton @ ncdenr.gov
Arcadis
[e-mail]
Page 3 of 3
Interim Inspection of
October 8, 2010
List of Attendees:
Dan Brown, PE
Roanoke Rapids Sanitai^|i
WWTP Sodium Hypocl^m
CS 370 449-04
As-builts or Record Drawings - were reviewed at today's meeting. Please have these available
for review at all meetings.
Dear Mr. Brown:
NCQQ242Q1
2.
3.
4.
5.
Mr. R. Danieley Brown, CEO
Roanoke Rapids Sanitary District
P.O. Box 308
Roanoke Rapids, NC 27870
Beverly Eaves Perdue
Governor
Raleigh Regional Office
1628 Mail Service Center
Phone [phone]
FAX [phone]
Dee Freeman
Secretary
North Carolina Division of Water Quality Raleigh Regional Office Surface Water Protection
Internet: www ncwaterquality org 1628 Mail Service Center Raleigh, NC 27699-1628
An Equal Opportunity/Affirmative Action Employer - 50% Recycled/10% Post Consumer Paper
Subject: Compliance Evaluation Inspections
Roanoke Rapids Sanitary District WWTP
NPDES Permit No. NC0024201
and Stormwater Permit No. NCG110091
Halifax County
Mair
NCDENR
North Carolina Department of Environment and Natural Resources
Division of Water Quality
Coleen H. Sullins
Director
October 25, 2010
North Carolina— Naturally
Customer Service
877-623-6748
A
Two drying beds were in use, holding anaerobic digester solids. They will remain
until early in 2011 in order to meet 503 regulations before being land applied.
The secondary effluent discharge system that involves a diesel driven pump for
times when high river flow covers the gravity discharge structure is exercised
regularly. The engine is run monthly, and is put under a load quarterly when the
effluent is discharged during the day shift via that release point.
The effluent flow meter is officially calibrated more often than the annual
requirement. It is calibrated quarterly and checked against a staff gage weekly by
the staff of operators.
Both primary clarifiers have received overhauls of the rake mechanism in recent
weeks.
On October 19, 2010 Myrl Nisely of the Raleigh Regional Office conducted a compliance
inspection of the Sanitary District WWTP. Along with that inspection, a stormwater
compliance inspection was also carried out. The assistance of Gregg Camp was
appreciated. The inspection checklists are attached. The plant was in compliance with
both permits. Comments are as follows:
1. The description of the WWTP will be changing. When the process of renewing the
WWTP permit is undertaken at least 180 days before the permit expires in March,
2012, be sure to include a description of the new hypochlorite disinfection and
dechlor system. Include the bermed unloading pad with a drain to the drying bed
return line. The system is expected to go online in about a month. Delivery delays
have caused the startup to be late.
Page 2 of 2
cc: RRO/SWP files
Central Files
Myrl A. Nisely
Environmental Chemist
Sincerely,
A
4
Roanoke Rapids Sanitary District CEI, October 2010
The stormwater program is being followed. See the attached checklist. There is a pump
station near the influent pump house that is used to transfer stormwater from that area to
Chockyotte Creek when the Roanoke River is high.
Employee training for 2010 has not been completed.
If you have any questions or comments, please call me at 919-791-4255.
6. Gregg maintains two ORC logs - an operation log and a DMR review log. These
provide evidence a good level of awareness of plant performance on a daily basis.
NCG110091
EPA
NPDES
J11NC0024201
LI I I I I I I I I I I | | | | | | | | | | | pe
Entry Time/Date Permit Effective Date
07/07/0112:45 PM 10/10/19
Exit Time/Date Permit Expiration Date
Weldon NC 27890
12/03/3102:20 PM 10/10/19
Other Facility Data
Alan Gregg Camp/ORC/919 536 4884/
Records/Reports
Facility Site Review Effluent/Receiving Waters
Section D:
(See attachment summary)
Name(s) and Signature(s) of Inspector(s)Agency/Office/Phone and Fax Numbers Date
Myrl Wisely RRO WQ//919 7914200/
Page #1
12,
Roanoke Rapids WWTP
135 Aqueduct Rd
United States Environmental Protection Agency
Washington, D C. 20460
yr/mo/day
10/10/19
Bl71 u
Contacted
No
QA
72LI
Form Approved.
OMB No. 2040-0057
Approval expires 8-31-98
Name(s) of Onsite Representative(s)/Titles(s)/Phone and Fax Number(s)
///
Inspection Work Days
67|l 69
Facility Self-Monitoring Evaluation Rating
____ 70U
Fac Type
2°U
Section C:
Flow Measurement
| Sludge Handling Disposal
Inspection Type
18LI
Areas Evaluated During Inspection (Check only those areas evaluated)
Operations & Maintenance
J17
Inspector
19|±l3l
73| | I74
Water Compliance Inspection Report
Section A: National Data System Coding (i.e., PCS)
—Reserved---------------------
75| I I I I I I I 80
Signal^of ManagemenLdA Review/ a / 7 Agency/Office/Phone and Fax Numbers Date
EPA Form 3560-3 (Rev 9-94) Previous editions are obsolete
■ Permit
■ Self-Monitoring Program
Laboratory
_______________________________________________Section B: Facility Data______
lndUS,rial Users Urging to POTW. also include
n-,. . . . RemarksI I I I I I I I I I I I I I I I I I I I I I I
Name, Address of Responsible Official/Title/Phone and Fax Number
£™^<7ley Box 308 Roanoke Rapids NC
27870//252-537-9137/2525379136
Summary of Finding/Comments (Attach additional sheets of narrative and checklists as necessary)
Transaction Code
1 U 2 u
Operations & Maintenance Yes No NA NE
Judge, and other that are applicable?
Comment:
Permit Yes No NA NE
O ■
■ ODD
# Are there any special conditions for the permit?O ■
Is access to the plant site restricted to the general public?■
Is the inspector granted access to all areas for inspection?■
Comment:
Record Keeping Yes No NA NE
Are records kept and maintained as required by the permit?■ □00
Is all required information readily available, complete and current?■ ODO
■ ODD
■ 000
Is the chain-of-custody complete?■ 000
Dates, times and location of sampling
Name of individual performing the sampling
Results of analysis and calibration
Dates of analysis
Name of person performing analyses
Transported COCs 0
Are DMRs complete: do they include all permit parameters?■ 000
Has the facility submitted its annual compliance report to users and DWQ?■ 0 00
■ 000
■ non
Is the ORC certified at grade equal to ■ 000
Is the backup operator certified at one grade less or greater than the facility classification?■ 00 0
Is a copy of the current NPDES permit available on site?■ ODD
Page #3
Permit: NC0024201
Inspection Date: 10/19/2010
Owner - Facility: Roanoke Rapids WWTP
Inspection Type: Compliance Evaluation
(If the facility is or > 5 MOD permitted flow) Do they operate 24/7 with a certified operator on each shift?
Is the ORC visitation log available and current?
Are all records maintained for 3 years (lab. reg. required 5 years)?
Are analytical results consistent with data reported on DMRs?
(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?
or higher than the facility classification?
Is the plant generally clean with acceptable housekeeping? ■ O O O
Does the facility analyze process control parameters, for ex: MLSS, MCRT, Settleable Solids. pH, DO, Sludge ■ O
Record Keeping Yes No NA NE
■ O
Effluent Pipe Yes No NA NE
Is right of way to the outfall properly maintained?■
Are the receiving water free of foam other than trace amounts and other debris?■ ODO
■
Flow Measurement - Effluent Yes No NA NE
# Is flow meter used for reporting?■
Is flow meter calibrated annually?■ o
Is the flow meter operational?■ o
(If units are separated) Does the chart recorder match the flow meter?■
Comment:Calibrated 9/29/10
Anaerobic Digester Yes No NA NE
Type of operation:Floating cover
Is the capacity adequate?■ o
# Is gas stored on site?■ ODO
Is the digester(s) free of tilting covers?■ 0
Is the gas burner operational?■ o
Is the digester heated?■ o o
Is the temperature maintained constantly?■ o
Is tankage available for properly waste sludge?■ o
Comment:
Drying Beds Yes No NA NE
Is there adequate drying bed space?■
Is the sludge distribution on drying beds appropriate?■ ODD
Are the drying beds free of vegetation?■
# Is the site free of dry sludge remaining in beds?O ■ O
Is the site free of stockpiled sludge?0 ■
Is the filtrate from sludge drying beds returned to the front of the plant?■ 0
Page #4
Permit: NC0024201
Inspection Date: 10/19/2010
Owner - Facility: Roanoke Rapids WWTP
Inspection Type: Compliance Evaluation
If effluent (diffuser pipes are required) are they operating properly?
Comment:
Facility has copy of previous year's Annual Report on file for review?
Comment:
Drying Beds Yes No NA NE
# Is the sludge disposed of through county landfill? ■
# Is the sludge land applied?■
(Vacuum filters) Is polymer mixing adequate? 0 ■
Two beds are in use, and sludge is stockpiled for periods until it is taken
Yes No NA NE
■ ODO
Is the chemical feed equipment operational?■
Is storage adequate?■
Is the site free of high level of solids in filtrate from filter presses or vacuum filters?o ■
Is the site free of sludge buildup ■
o ■
■ o
Bar Screens Yes No NA NE
Type of bar screen
a.Manual
b.Mechanical
Are the bars adequately screening debris?■ 0
Is the screen free of excessive debris?■ ODO
Is disposal of screening in compliance?■ ODO
Is the unit in good condition?■ 0
Comment:
Grit Removal Yes No NA NE
Type of grit removal
a.Manual
b.Mechanical
Is the grit free of excessive organic matter?■ o
Is the grit free of excessive odor?■ o o
# Is disposal of grit in compliance?■ 0 0
Page #5
Comment:
away by Synagro
Permit: NC0024201
Inspection Date: 10/19/2010
Owner - Facility: Roanoke Rapids WWTP
Inspection Type: Compliance Evaluation
The facility has an approved sludge management plan?
Comment:
Solids Handling Equipment
Is the equipment operational?
on belts and/or rollers of filter press?
Is the site free of excessive moisture in belt filter press sludge cake?
Grit Removal Yes No NA NE
Comment:
Primary Clarifier Yes No NA NE
Is the clarifier free of black and odorous wastewater?■ o
Is the site free of excessive buildup of solids in center well of circular clarifier?■ 0
Are weirs level?■ o
Is the site free of weir blockage?■
Is the site free of evidence of short-circuiting?■
Is scum removal adequate?■ o
Is the site free of excessive floating sludge?■ o
Is the drive unit operational?■ o
Is the sludge blanket level acceptable?■ o
■
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?■ o o
Is the site free of weir blockage?■
Is the site free of evidence of short-circuiting?■ o
Is scum removal adequate?■ o
Is the site free of excessive floating sludge?■ o
Is the drive unit operational?■
Is the return rate acceptable (low turbulence)?■ o
Is the overflow clear of excessive solids/pin floc?■
■
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?■ ODO
Is the distribution of flow even from the distribution arms?■ o
Page #6
Permit: NC0024201
Inspection Date: 10/19/2010
Owner - Facility: Roanoke Rapids WWTP
Inspection Type: Compliance Evaluation
Is the sludge blanket level acceptable? (Approximately 'A of the sidewall depth)
Comment:
Is the sludge blanket level acceptable? (Approximately 7< of the sidewall depth)
Comment:
Trickling Filter Yes No NA NE
Is the filter free of uneven or discolored growth?■ o
Is the filter free of sloughing of excessive growth?■ o
Are the filter’s distribution arms orifices free of clogging?■ o
Is the filter free of excessive filter flies, worms or snails?■ 0
Comment:
Aeration Basins Yes No NA NE
Mode of operation Plug flow
Type of aeration system Diffused
Is the basin free of dead spots?■
Are surface aerators and mixers operational?o ■
Are the diffusers operational?■ o
Is the foam the proper color for the treatment process?■ □00
Does the foam cover less than 25% of the basin’s surface?■ 000
Is the DO level acceptable?■ 000
■ ODD
De-chlorination Yes No NA NE
Type of system ?Gas
Is the feed ratio proportional to chlorine amount (1 to 1)?■ n n o
Is storage appropriate for cylinders?■ 0 0 0
# Is de-chlorination substance stored away from chlorine containers? ■ o
Are the tablets the proper size and type? ■
Small cyclinders are in temporary use until the new hypo system is
Are tablet de-chlorinators operational? o ■ o
Number of tubes in use?
Comment:
Standby Power Yes No NA NE
Is automatically activated standby power available?■ o o
Is the generator tested by interrupting primary power source?■
Page #7
Comment:
operational.
Is the DO level acceptable?(1.0 to 3.0 mg/l)
Comment:
Permit: NC0024201
Inspection Date: 10/19/2010
Owner - Facility: Roanoke Rapids WWTP
Inspection Type: Compliance Evaluation
Standby Power Yes No NA NE
■ Is the generator tested under load?
■ Was generator tested & operational during the inspection?
Do the generator(s) have adequate capacity to operate the entire wastewater site?■
■ oIs there an emergency agreement with a fuel vendor for extended run on back-up power?
■ Is the generator fuel level monitored?
Laboratory Yes No NA NE
■ O Are field parameters performed by certified personnel or laboratory?
■ ODDAre all other parameters(excluding field parameters) performed by a certified lab?
■ o # Is the facility using a contract lab?
■ # Is proper temperature set for sample storage (kept at less than or equal to 6.0 degrees Celsius)?
■ ODDIncubator (Fecal Coliform) set to 44.5 degrees Celsius*/- 0.2 degrees?
■ Incubator (BOD) set to 20.0 degrees Celsius +/- 1.0 degrees?
Comment:
Disinfection-Liquid Yes No NA NE
■ O Is there adequate reserve supply of disinfectant?
o ■ (Sodium Hypochlorite) Is pump feed system operational?
■ o Is bulk storage tank containment area adequate? (free of leaks/open drains)
■ o Is the level of chlorine residual acceptable?
■ Is the contact chamber free of growth, or sludge buildup?
■ o Is there chlorine residual prior to de-chlorination?
Comment:
Influent Sampling Yes No NA NE
■ # Is composite sampling flow proportional?
■ Is sample collected above side streams?
■ Is proper volume collected?
■ Is the tubing clean?
■ o # Is proper temperature set for sample storage (kept at less than or equal to 6.0 degrees Celsius)?
Page #8
Owner - Facility: Roanoke Rapids WWTP
Inspection Type: Compliance Evaluation
Permit: NC0024201
Inspection Date: 10/19/2010
Comment: Generator engine is run monthly, tested under a load quarterly, and
typically used about 20 times/yr for 7 hours per day for load shedding for Dominion
Power.
f
Influent Sampling Yes No NA NE
■ OOOIs sampling performed according to the permit?
Comment:Temperature = 2.4 deg C
Effluent SampHng Yes No NA NE
■ ODOIs composite sampling flow proportional?
■ ODDIs sample collected below all treatment units?
Is proper volume collected?■ ODD
Is the tubing clean?■ ODD
■ ODO# Is proper temperature set for sample storage (kept at less than or equal to 6.0 degrees Celsius)?
■ 000
Page #9
Permit: NC0024201
Inspection Date: 10/19/2010
Owner - Facility: Roanoke Rapids WWTP
Inspection Type: Compliance Evaluation
Is the facility sampling performed as required by the permit (frequency, sampling type representative)?
Comment: Temperature = 0.9 deg C
t
September 29, 2010
Dear Mr. Brown:
GWILtavh
cc:
attachment: Project Closeout Checklist
You should review this report, take actions or provide responses as indicated and then file
with your project records. If you have any questions please contact me at [phone] or via
e-mail [e-mail].
Beverly Eaves Perdue
Governor
Subject: Interim Inspection
Roanoke Rapids SD [Halifax]
WWTP Sodium Hypochlorite System
Project No. CS 370 449-04
Dee Freeman
Secretary
Mr. R. Daniel Brown. PE
Roanoke Rapids Sanitary District
PO Box 308
Roanoke Rapids, North Carolina 27870
Hunter Carson. PE, Arcadis
Danny Smith. Raleigh Regional DWQ Office
SRF
HCDEHR
North Carolina Department of Environment and Natural Resources
Division of Water Quality
Coleen H. Sullins
Director
Sincerely, /
cJ
Gerald W. Horton, PE
Environmental Engineer
Construction Inspection Group
NorthCarolinaNaturally
FASHAREXProjBCt Management Branch\Group - Construction lnspection\Projects (ActivE)\Raanoke Rapids SRF gvAiMnt Insp 10-09-11] RnanoFeRapids doc
Construction Grants & Loans Section
1633 Mail Service Center Raleigh NC 27699-1633
Phone:[phone] / FAX: [phone] / Internet: http://portal.ncdenr.org
An Equal Opportunity/Affirmative Action Employer
The Construction Inspection Group (CIG) of the Construction Grants and Loans Section
performed an interim inspection for the state and federally funded portion of subject project
at 11:00 am Friday September 10, 2010. Monthly progress meetings are normally scheduled for
the 2nd Friday each month. Location of the Progress meetings is the WWTP located on Aquaduct
Rd. The next scheduled progress meeting and interim inspection is Friday October 8, 2010.
Contract completion date remains December 3, 2010.
I
1.
4.
5.
16.
17.
18.
19.
RFPs Status - none pending
RFIs Status - WWS asked who furnishes chemicals for new tanks
Page 2 of 3
Interim Inspection of
September 10, 2010
CHANGE ORDER UPDATE - CG&L previously requested Change order #1. Owner and
Engineer are advised - if Owner wishes for items to be eligible for funding, a change order should
be submitted. This is not a guarantee it will be approved by CG&L. The same applies for CO#2
and any subsequent COs.
CONTRACT:
WWTP Sodium Hypochlorite System - Water & Waste Systems Construction, Inc., (WWS)
9700 Ten-Ten Rd.. Raleigh, NC 27603
GENERAL CONCERNS / RECOMMENDATIONS / ACTION ITEMS -Please note UPDATES
on Comments and Concerns noted in previous progress meetings (for reference) are italicized.
September update: VVVV.S’ did not provide update construction schedule at this meeting.
CG&L requests the updated schedule be submitted via email. August - Water & Waste
Systems, Inc. (WWS) maintains they will complete job on time or ahead of time. May -
WWS proclaims to be on schedule and will finish on time if no problems encountered.
September update: tank manufacturer will be on site next week (Sept. 17-week of) to make
repairs. Owner is concerned with quality of tank and warranty offered. Mr. Brown asked
that he be provided written warranty adjustment and information. August - there have
been numerous problems with the tanks, such as lift eyes being knocked off or damaged,
damage to tank wall, access in wrong orientation. WWS must resolve these issues. Owner
advised and requested WWS to expedite and pressure the FRP tank manufacturer for
delivery. It was related that the tanks are delayed and anticipated in July. Effect is it
restricts when prefab building and roof can be erected.
September update: building by ARCO is scheduled for start of erection on Monday Sept.
13. Erection can finally initiate now as tanks have been set in place. August - WWS
anticipates constructing building in the next weeks. Pre-Engineered metal building is
manufactured by ARCO and will be installed by Rabon.
September update: CG&L reviewed inspection logs which are kept on lap top computer.
The logs were deemed adequate. Comment from earlier meetings: G&L requests
Inspection logs be available for review at all meetings.
September update: CG&L reviewed record drawing markups, they appeared to be
complete. Comment from earlier meetings: Please have record drawing (as-builts) markups
available for review at next meeting and all subsequent meetings.
September update: nothing yet submitted. IMPORTANT - O&M must be approved by
CG&L before reimbursements beyond 95% will be made. Submit O&M Manual to the
attention ofKavitha Ambikadevi. CG&L advised Owner and Engineer an O&M Manual is
required for the new work and also a closeout checklist should be provided for possible
Final inspection at next meeting. CG&L sent via email: 1) closeout checklist,
2) O&M preparation guidance document and 3) Owner O&M review form.
In preparation for Final inspection, attached please find Project Closeout Checklist.
LOAN DISBURSEMENTS
The loan is for maximum 20 years at interest rate of 2.5 %. As of Sept 20 reimbursements for
the construction contract total $438,139, 49%. This compares to 73% of the time has elapsed
on contract.
Roanoke Rapids Sanita^Bhstrict
WWTP Sodium Hypochlorite System
CS 370 449-04
Project Schedule - WWS is contemplating finishing in September.
Signage - Project sign has been erected and information for OSHA, wage rates etc. are posted.
252 537-9132
Gregg Camp 252 536-4884
Justin Blackmon 252 537-9137
Craig Williams 252 536-4884
Hunter Carson, PE 919 854-1282
Billy Clinard 919 625-8864
Brandon Clinard
919 715-6219Gerald W. Horton, PE
(
SUBMITTAL Status- all submittals have been approved, but fiberglass re-submittals are still
outstanding.
Inspectors logs/Work Orders - CG&L requests these be available for review at all meetings.
Inspection is part time and on as needed basis. Inspection logs were reviewed at today's meeting
and deemed adequate.
Roanoke Rapids San. Disk, Director
[e-mail]
Roanoke Rapids San. Dist.
[e-mail]
Roanoke Rapids San. Dist., Constr. Obsrv.
[e-mail]
Roanoke Rapids San. Dist.. Supv.
c wi 11 iams @ rrsd. org
Water & Waste Systems Constr., Inc.,
bclinard @ wwsys.com
Water & Waste Systems Constr., Inc.,
NC Construction Grants & Loans
gerald. horton @ ncdenr.gov
Arcadis
[e-mail]
Page 3 of 3
Interim Inspection of
September 10, 2010
Roanoke Rapids Sanitary District
WWTP Sodium Hypochlorite System
CS 370 449-04
List of Attendees:
Dan Brown, PE
As-builts or Record Drawings - were reviewed at today's meeting. Please have these available
for review at all meetings.
rr
ENGINEER'S RESPONSIBILITIES:
FOR EACH CONTRACT:
17.
18.
19.
22.
OWNER / NAME:
ENGINEER:
Approved Plans and Specifications in owner’s possession.
As-Built/Record Drawings (certified/sealed) provided to owner
Test Reports: pipe/pressure tests recorded, concrete, compaction etc.
Inspector’s Daily Logs
Approved shop drawings and submittals provided to owner
Warranty Information provided to owner.
Spare Parts Inventory and List provided to owner.
Training, training sessions done by whom, when, what subject.
Release/Approval from NC-DOT and/or Rail Roads (if Applicable)
Engineer's Certification
Operation and Maintenance Manuals (O&M), if required (SRF Only)
PROJECT NO:
DESCRIPTION:
20.
21.
12.
13.
14.
L
2.
_3-
4.
5.
6.
7.
8.
.9.
10.
II.
15.
16.
Final adjusting Change Order (must match Final Reimbursement Request)
Release of Liens & Consent of Surety to final payment
Final Sales Tax Report
715-6216 (State Programs. STAG):
715-6218 (Reimbursements):
At Final, CG&L inspector will wish to have available for review or discussion ALL
applicable items listed above. To closeout project loan and/or grant, please provide any
other documentation CG&L inspector states or requests in the Final Inspection report.
OWNER (Prepare, sign, submit or confirm, as applicable, the following):
Final Reimbursement Request and supporting invoices. All costs must be approved by CG&L.
Owners Certification of Completion, acceptance of the completed project.
(This form now satisfies the requirement for a separate Initiation of Operation Letter.)
Clear Site/Easement Certification (a) by Owner & (b) by Owner’s Counsel (Done during
design & prior to construction, IF easements were added or changed, this must be redone)
STAG projects closeout items also include a final MBE. WBE and Quarterly Report, the
Final Reimbursement Request form, and the Lobbying Certification. They can be found on
our website, (www.nccgl.net).
Performance Certification (is required on a few Treatment Plan Projects and is due one year
after the completion date.)(SRF only)
Is Closing cost Paid? If yes. provide the date of Payment. If No, forward to Leslie Rogers.
ARRA Projects: Make available for review -Davis-Bacon Interviews. Standard Form 1445,
Certified payroll records for ALL primes and subs as required in guidance, and Buy
American documentation for all materials, equipment and manufactured goods incorporated
into project.
Submittal of form 6100-2, indicating actual amounts paid to DBE firms (SRF Only).
Turn Over to the Owner: 1, 2, 3, 4. 5, 6, 7. 8, 9, 13, 21
Submit above items to the following Construction Grants & Loans staff:
Kavitha Ambikadevi 919 715-6200 (SRF): 10, 11, 16, 17, 18, 19,20,22
or Don Evans 919 715-6216 (State Programs, STAG): 10, 11, 16, 17, 18, 19,20,22
Leslie Rogers 919 715-6218 (Reimbursements): 14, 15 and 20 if applicable.
CG&L Inspector:
NC Construibon Grants & Loans Prompt Closeout Checklist
NCDENR
Phone [phone]; FAX [phone], Forms & other information available at http.7/portal.ncdenr.org
Division of Water Quality, Construction Grants & Loans Section
1633 Mail Service Center, Raleigh, NC 27699-1633
I
August 25, 2010
Dear Mr. Brown:
fikerely.
GWIV-wh
cc:
You should review this report, take actions or provide responses as indicated and then file
with your project records. If you have any questions please contact me at [phone] or via
e-mail [e-mail].
Beverly Eaves Perdue
Governor
F \SHARE\Prcject Management BranchXGroup - Construetinn Inspectinn\Projects (Active)\RoanoFe RapidsMnt Insp IO-08-04 RoanokeRapids doc
Construction Grants & Loans Section
1633 Mail Service Center Raleigh NC 27699-1633
Phone:[phone] / FAX: [phone] / Internet: http://portal.ncdenr.org
An Equal Opportunity'Affirmative Action Employer
Hunter Carson, PE, Arcadis
Danny Smith, Raleigh Regional DWQ Office
SRF
Mr. R. Daniel Brown, PE
Roanoke Rapids Sanitary District
PO Box 308
Roanoke Rapids, North Carolina 27870
NorthCarolinaNaturally
Subject: Interim Inspection
Roanoke Rapids SD [Halifax]
WWTP Sodium Hypochlorite System
Project No. CS 370 449-04
The Construction Inspection Group (CIG) of the Construction Grants and Loans Section
performed an interim inspection for the state and federally funded portion of subject project
at 11:00 am Wednesday August 4, 2010. There was no July meeting. This interim inspection was
rescheduled from July 9. Monthly progress meetings are normally scheduled for the 2"a Friday
each month. Location of the Progress meetings is the WWTP located on Aquaduct Rd. The next
scheduled progress meeting and interim inspection is Friday September 10, 2010. which may be a
Final inspection by CG&L. Contract completion date remains December 3, 2010.
NCDENR ^0^201
North Carolina Department of Environment and Natural Resources
Division of Water Quality
Coleen H. Sullins
Director
Dee Freeman
Secretary
------
Gerald W. Horton, PE
Environmental Engineer
Construction Inspection Group
1.
4.
5.
8.
9.
18.
RFPs Status - none pending
RFIs Status - WWS asked who furnishes chemicals for new tanks
Project Schedule - WWS is contemplating finishing in September.
Signage - Project sign has been erected and information for OSHA, wage rates etc. are posted.
SUBMITTAL Status- all submittals have been approved.
CHANGE ORDER UPDATE - CG&L previously requested Change order #1. Owner and
Engineer are advised - if Owner wishes for items to be eligible for funding, a change order should
be submitted. This is not a guarantee it will be approved by CG&L. The same applies for CO#2
and any subsequent COs.
16.
17.
Page 2 of 3
Interim Inspection of
August 4, 2010
CONTRACT:
WWTP Sodium Hypochlorite System - Water & Waste Systems Construction, Inc., (WWS)
9700 Ten-Ten Rd., Raleigh, NC 27603
GENERAL CONCERNS / RECOMMENDATIONS / ACTION ITEMS -Please note UPDATES
on Comments and Concerns noted in previous progress meetings (for reference) are italicized.
August update: Water & Waste Systems, Inc. (WWS) maintains they will complete job on
time or ahead of time. May - WWS proclaims to be on schedule and will finish on time if
no problems encountered.
August update: there have been numerous problems with the tanks, such as lift eyes being
knocked off or damaged, damage to tank wall, access in wrong orientation. WWS must
resolve these issues. Owner advised and requested WWS to expedite and pressure the FRP
tank manufacturer for delivery. It was related that the tanks are delayed and anticipated in
July. Effect is it restricts when prefab building and roof can be erected.
August update: WWS anticipates constructing building in the next weeks. Pre-Engineered
metal building is manufactured by ARCO and will be installed by Rabon.
August update: the correct glue/solvent was used. June - Arcadis Whit Wheeler cautioned
WWS to use the correct glue on the Sched. 80 PVC pipe and the correct threads where/if
necessary.
August update: WL were satisfactorily tested and Bac-T tests were successful.
April - Waterline to be disinfected week of May 16.
CG&L requests Inspection logs be available for review at all meetings.
Please have record drawing (as-builts) markups available for review at next meeting and all
subsequent meetings.
CG&L advised Owner and Engineer an O&M Manual is required for the new work and
also a closeout checklist should be provided for possible Final inspection at next meeting.
CG&L sent via email: 1) closeout checklist, 2) O&M preparation guidance document and
3) Owner O&M review form.
LOAN DISBURSEMENTS
The loan is for maximum 20 years at interest rate of 2.5 %.
Roanoke Rapids Saniti^B)istrict
WWTP Sodium Hypoc^forite System
CS 370 449-04
252 537-9132
Gregg Camp 252 536-4884
Justin Blackmon 252 537-9137
Craig Williams 252 536-4884
Hunter Carson, PE 919 854-1282
Billy Clinard 919 625-8864
Gerald W. Horton, PE 919 715-6219
Inspectors logs/Work Orders - CG&L requests these be available for review at all meetings.
Inspection is part time and on as needed basis.
Waler & Waste Systems Constr., Inc.,
[e-mail]
NC Construction Grants & Loans
geral d. horton @ ncde nr. go v
Arcadis
hunter.carson @ aarcadis-us.com
Page 3 of 3
Interim Inspection of
August 4, 2010
Roanoke Rapids Sanitary District
WWTP Sodium Hypochlorite System
CS 370 449-04
Roanoke Rapids San. Dist., Director
[e-mail]
Roanoke Rapids San. Dist.
[e-mail]
Roanoke Rapids San. Dist., Constr. Obsrv.
jblackmon @ rrsd.org
Roanoke Rapids San. Dist., Supv.
c wil hams @ rrsd .org
List of Attendees:
Dan Brown, PE
As-builts or Record Drawings - were reviewed. Please have these available for review at all
meetings.
( Pi.
lural Res< jrces
April 22, 2010
Dear Mr. Brown :
Sipcerely,
cc:
Beverly Eaves Perdue
Governor
Mr. R. Daniel Brown, PE
Roanoke Rapids Sanitary District
PO Box 308
Roanoke Rapids, North Carolina 27870
Construction Grants & Loans Section
1633 Mail Service Center Raleigh NC 27699-1633
Phone:[phone] / FAX. [phone] / Internet: www.nccgl.net
An Equal Opportunity/Affirmative Action Employer
Subject: Initial Interim inspection
Roanoke Rapids SD [Halifax]
WWTP Sodium Hypochlorite System
Project No. CS 370 449-04
Gerald W. Horton, Pb
Environmental Engineer
Construction Inspection Group
• 2^
NCDENi
North Carolina Department of Environm nt and
Division of Water C .ality
Coleen H. Sullins
Director
North Carolina
^aturalhj
Dee Fre<7 an
Secre y
You should review this report: take actions or provide responses as indicated and then file
for your records. If you have any questions please contact me at * 919) 715-6219 or via e-mail
[e-mail].
Hunter Carson, PE, Arcadis
Danny Smith, Raleigh Regional DWQ Office
CIG - Mark Hubbard. PE
SRF
The Construction Inspection Group (CIG) of the Construction Grants and Loans Section
performed an interim inspection for the state and federally funded portion of subject project at
10:30 am on Friday April 9, 2010. This interim inspection was conducted in conjunction with the
monthly progress meeting normally scheduled for the 2" Friday each month. Location of the
Progress meetings is the WWTP located on Aquaduct Rd. The next scheduled progress meeting
and interim inspection is May 14. Contract completion date remains December 3, 2010.
' J
o
construct and install instrumentation and controls,
demolition and modifications to existing building converting it to sodium­
bisulphite building,
construct hypochlorite building to house related facilities.
Page 2 of 3
Interim Inspection of
April 9, 2010
Roanoke Rapids Sani
WWTP Sodium Hype
CS 370 449-04
CONTRACT:
WWTP Sodium Hypochlorite System - Water & Waste Systems Construction, Inc., (WWS)
9700 Ten-Ten Rd., Raleigh, NC 27603
LOAN DISBURSEMENTS
As of April 9, 2010 no reimbursements have been sought from CG&L. Closing costs are 2%
of the eligible loan amount, thus $22,216. The loan is for maximum 20 years at interest rate of 2.5 %.
District
;^^jrite System
CONSTRUCTION INSPECTION
Observations of WWS construction and progress:
1. WWS completed 6" waterline.
2. Poured SHB footings.
3. Chlorine contact pumped out in preparation for work therein. WWS is to install Owner
provided equipment. All equipment has been delivered except for the pumps.
Description of Eligible work :
o
o
GENERAL CONCERNS / RECOMMENDATIONS / ACTION ITEMS -Please note UPDATES
on Comments and Concerns noted in previous progress meetings (for reference) are italicized.
1. IMPORTANT: After meeting CG&L walked construction area and observed the excavation
for the proposed Sodium Hypochlorite Building (SHB) had standing water. Owner and
Engineer are advised to have sub-grade tested before allowing further work or pouring of
concrete foundation or slab. CG&L requests being advised of results and viewing
documentation at May meeting.
2. Dan Brown noted reinforcement is being bent in field. CG&L asks Engineer to respond to
this concern in writing. Engineer should address shop drawings and specifications on this
matter.
3. WWS will have project sign erected shortly after sign information is provided from Engineer.
4. Engineer inquired if CG&L had received Change Order #1. Upon returning to office, Horton
found CO#1 was received via email March 22, 2010. An original signature page is needed.
CO#1 is under review.
5. April Update: Construction Schedule was provided. Schedule lacks specificity, a revised
schedule should be provided at the May 6 meeting. CG&L requests construction schedule be
provided at next meeting.
6. April Update: submittal log was provided. CG&L asks updated submittal log be provided at
May 6 meeting and be expanded to include all submittals, ie, listing those yet to be submitted
also. Owner and Engineer are requested to have a submittal log available for review at next
and all subsequent meetings until all submittals have been approved.
7. CG&L requests Inspection logs be available for review at all meetings.
8. Please have record drawing (as-builts) markups available for review at next meeting and all
subsequent meetings.
o
o
252 537-9132
Gregg Camp 252 536-4884
Justin Blackmon 252 537-9137
Craig Williams 252 536-4884
Hunter Carson, PE 919 854-1282
Billy Clinard 919 625-8864
Gerald W. Horton. PE 919 715-6219
o
o
o
o
o
Roanoke Rapids San. Exist.. Director
dbro w n @ nsd.org
Roanoke Rapids San. Exist.
gcamp @ nsd.org
Roanoke Rapids San. Exist.. Constr. Obsrv.
[e-mail]
Roanoke Rapids San. Exist.. Supv.
cwi 11 iams @ rrsd.org
Arcadis
hunter.carson @ aarcadis-us.com
Water & Waste Systems C instr., Inc.,
be 1 i n aid @ w w sy s .com
NC Construction Grants & Loans
[e-mail]
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;
dechlorination system consisting of a
■ 4,470 gallon bulk sodium bisulphite storage tank and
■ two (2) 3 GPH metering feed pumps;
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.
Roanoke Rapids Sanitary District
WWTP Sodium Hypochlorite Sysl
CS 370 449-04
Page 3 of 3
Interim Inspectiv i of
April 9. 2010
List of Attendees:
Dan Brown, PE
CHANGE ORDER UPDATE - CO#1 has been received and is under review.
RFPs Status - none pending
RFIs Status - none pending
Project Schedule - WWS needs to provide revised Construction Schedule
Signs - ARRA signs have been erected and information for OSHA. wage rates etc. are posted
SUBMITTAL Status- please have complete submittal log available for review at next meeting.
Inspectors logsAVork Orders - CG&L requests these be available for review' at all meetings.
As-builts or Record Drawings - were reviewed. Please have these available lor review at all
meetings.
J
PROPOSAL
Date 2/11/2010
Proposal #10D1123
Sales Person DK
Quantity Description Rate Amount
1 SECTION 17025 FIELD INSTRUMENTS
2 4SO.OO 960.00
5 90.00 450.00
3 2,715.00 8,145.00
1 3,115.00 3,115.00
Total:
Page 2
Part 2.7 (A-E)
Ultrasonic Level Transmitters
Tag: LE/L1T-101, LE/L1T-102; LEA.1T-203
Manufacturer: Endress & Hauser
Model (Transmitter): FMU90-R11CA111AAIA
Model (Transducer): FDU91-RN IAA6"
Modified Flange: Chcmtrol 1853-H60
Carolina Technical Services, Inc.
Post Office Box 268
China Grove, NC 28023
704.857.1115 / 704.625.7425 Fax
Federal ID: 56-2120646
Part 2.7 (A-E)
Ultrasonic Level Transmitters
Tag: LE/LIT-20l_LE/LIT-202
Manufacturer: Endress & Hauser
Model (Transmitter): FMU90-R11CA212AA1A
Model (Transducer): FDU91-RN4AA6"
Modified Flange: Chenitrol 1853-H60
Part 2.6 (A-B)
Chemical Emergency Hand Switches
Tag: HS-101; HS-102: HS-103; HS-201; HS-202
Manufacturer: IDEC
Model: l-BlW-HW1B-V411R
Part 2.5 (A-D)
Chemical Emergency Audio / Visual Alarm Devices
Tag: A.A/VA-101; AA/AV-201
Manufacturer: Ingram Products, Inc.
Model: AVS115CLX40FS
Proposal for
Water & Waste Systems Construction, Inc.
Scott Leonard
14 Apothecary Ct.
Gamer, NC 27529
Ship To
Project: Roanoke Rapids WWTP
Chemical Feed Imporvements
Bid Date: 12-Nov-09
Engineer: Arcadis G&M of N.C.
Validity: 30 Days
Terms: Net 30
CTS' Conditions of Sale apply.
Total is less S&H and Taxes, (unless otherwise noted above)
PERFORMANCE ANNUAL REPORT 2009
ROANOKE RAPIDS SANITARY DISTRICT
I.GENERAL INFORMATION
B. Responsible entity: Roanoke Rapids Sanitary District, Dan Brown, CEO
C. Person in charge/contact
2.
D. Applicable Permit(s)
2.
E. Description of C.S.:
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 3 primary basin pump stations and 2 secondary
pump stations along the route. Pipe sizes for the Interceptor ranges from 18” to 30”.
The system has six sewer lift stations. Three stations are located in the Gaston, NC system. One of
these serves a Northampton County School, 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 and Poplar Springs, discharge to the Roanoke
River Interceptor while the Greenbriar Pump Station discharges to the Chockyotte Creek Outfall.
WWTP: NPDES NC0024201
Land Application (L.A.): WQ0001989
Stormwater (General): NCG110000
WWTP: Gregg Camp, Operator in Responsible Charge (ORC)
Roanoke Rapids Sanitary District, WWTP
135 Aqueduct Road
Weldon, NC 27890
Phone: [phone]
MAR 012010
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”.
A. Regulated entity: Roanoke Rapids Sanitary District, Collection Systems (C.S.) and
Wastewater Treatment Plant (WWTP)
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 wastewater to the WWTP.
DENR-WATER QUALITY
POINT SOURCE BRANCH
1. C.S.: North Carolina Environmental Management Commission System-wide Wastewater
Collection System Permit No. WQCS00027
1. C.S.: Charles Turner, Operator in Responsible Charge (ORC)
Roanoke Rapids Sanitary District
PO Box 308
Roanoke Rapids, NC 27870
Phone: [phone]
F. Description of WWTP:
II.PERFORMANCE
A. Description of overall 12 month performance, noting highlights and deficiencies:
The performance of the system in 2009 was good.
-2-
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.
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.
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.
The wastewater treatment plant is rated at 8.34 million gallons per day (MGD). Peak flow is rated at
12.5 MGD.
In 2009, the District had emergency bypass connection installed at the Housing Authority pump
station. All lift stations have emergency connections. In September, the District purchased a new
Preventive Maintenance of at least four hours a week cleaning sewer mains has also been a good
tool in reducing sewer backups. The District replaced 25 manhole vents on the Chockyotte
interceptor to be proactive in fighting Inflow and Infiltration from leaking and incorrect elevation
of existing manhole vents. 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. District staff conducted drawdown tests on 3
stations in 2009 to ensure proper performance.
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.
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 the 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.
2.
Some of the repairs and upgrades in 2009 include the following.
-3-
WWTP:
Overall performance for 2009 was good. There were no NPDES permit limits violations. (See
below) There were no monitoring or reporting violations.
Godwin Dri-prime pump compatible with all emergency connections, with enough capacity to
exceed any lift station.
In 2009, the District continued to be very active in maintenance issues and concerns. The WWTP
spent in excess of $739,000 on maintenance and repairs to equipment, supplies and materials
necessary to operate equipment and capitalized monies to replace and upgrade equipment.
The permit also contains daily maximum residual chlorine of 50 ug/1 (micrograms per liter or parts
per billion). Also permitted is pH. It must be maintained between 6 and 9 units. These two
samples are grab or instantaneously collected.
Current plant capacity is 8.34 million gallons per day (MGD) with a peak flow of 12.5 MGD. For
2009 the yearly average low flow was 3.2MGD with minimum of 2.7MGD. The yearly average
high flow was 6.5 MGD with a maximum of 13.7 MGD. The yearly average total flow was 4.1
MGD or 49% of the plant capacity. This is only a 100,000 gallon increase over the previous year
or less than 1%. Rain, which can affect flows by inflow and infiltration were nearly identical for
the past two years. In 2009, 46.5” of rain was recorded at the wastewater plant. The previous year
46.6” was recorded.
Grit collector. The grit collector removes grit from the influent flow. Grit is removed at this
location to prevent excessive wear on downstream equipment. There are two grit collectors. One
is the primary collector and the other is a back-up. The primary unit, installed in the mid 90’s,
uses a vortex motion to settle grit out of incoming wastewater. A pump removes the settled grit
from a hopper to a screw conveyor for removal to a dumpster. The back-up collector, original
equipment installed in the early 60’s, uses gravity to settle out grit. A sweeper arm moves the grit
to a hopper where a pump removes the settled grit to a screw conveyor for removal to a dumpster.
The pump in the back-up system failed and had to be repaired. Although much older and less
efficient than the newer vortex technology, the gravity system is maintained for use during times
when the vortex unit may be down for repairs.
The SCADA system that monitors all lift station 24 hours a day, 365 days a year has prevented lift
station overflows. In September 2009, level transducers were installed in all lift stations to show
an instantaneous wet well level to the water treatment plant operators through the SCADA system.
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.
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 21st by the governor, has heightened this
awareness. This bill codified as Chapter 329 session laws became effective October 1999.
Under the current permit, the District has a weekly effluent total suspended solids (TSS) limit of
45 mg/1 (milligrams per liter or parts per million) and a monthly limit of 30 mg/l. Also a weekly
carbonaceous biochemical oxygen demand (CBOD) limit of 37.5 mg/1 and a monthly limit of 25
mg/1. These two samples are composite collected. They are collected over a twenty four hour
period and on a flow proportional basis. The higher the flow, the more sample collected and
conversely, the lower the flow, less sample is collected. The yearly average for TSS was 16.2
mg/1 and CBOD was 5.8 mg/1. Using yearly average influent values for the same parameters this
calculates to a 93.0% and 98.2 % removal rate respectively. The permit requirement is 85%.
-4-
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. It collects floatable solids, mainly grease, and deposits it into a collection pit.
During past drainage for maintenance, inspections revealed severe deterioration of the base
support and water delivery piping. Due to the age (nearly 50 years) and style of primary clarifier,
repairing was not an option. There also had been several other substantial repairs over the years
and the overall condition of the entire unit was poor. Because of these reasons, it was decided to
replace the primary clarifier. Budget plans were set up for this to occur in fiscal year 2009-2010.
Specifications for the equipment were written up, advertised, and sent out to various vendors.
Bids were received and a purchase order issued to the winning bidder. Next specifications for
installation will be written up, advertised, and sent out to various contractors for installation of the
primary clarifier. This should occur in early 2010.
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 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. Each aeration basin has two air
lines which supplies air to the basins. All six lines have air isolation valves in line. The valves,
over twenty five years old, were broken or inoperable. They were replaced to restore control of air
line flow as needed. The secondary clarifier traveling siphon-bridge with skimmer arms is driven
by a motor and gearbox with chain and sprocket and a pulley cable system. The gearbox also has
a clutch to disengage the drive system in the event it gets in a bind. The traveling siphon bridge
and skimmer arm equipment had several repairs. A gearbox, motor and sprocket and chain wore
out and or failed. Associated with this was the deterioration of a clutch. A skimmer arm, which is
for removing floating materials from the surface of the secondary clarifier, is designed to glide
over the parts in the clarifier in performing but sometimes get out of adjustment. When this
happens, they can get bent or even pulled out of position. This is what occurred with one of the
four skimmer arms. It was formed back into shape, reattached and placed back in service. The
skimmer arms push floatable materials into a trough that is piped and valved to be either recycled
or removed. The valve on the removal line broke and was replaced. During replacement, part of
the line was replaced with stronger materials. The basins and clarifiers are piped to a drain station
with a pump. This pump station is used for draining the basins and clarifiers when access is
required for maintenance or taken off line due to operational mode. The drain pump, over twenty
five years old, stopped pumping. It was sent off for repairs but could not be repaired because of
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. All pumps are operated with a programmable
logic controller (PLC). The PLC is equipped with a human machine interface (HMI) which
allows users to make adjustments to the PLC. The HMI, which is touch screen operable, failed.
The HMI had to be replaced to restore full operational capability to the PLC.
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. During the exercising of one of these pumps, improper pump operation
was observed. Upon investigation, it was discovered that the coupling which connects the pump
shaft to the motor shaft was deteriorated. The coupling was replaced, making the pump available
for use again.
-5-
Digesters and Stabilization. Digesters receive solids removed from primary clarifiers. With heat
and mixing and occasional chemical addition for pH control, solids are stabilized. One of the
pumps used in the process re-circulates (mixes) solids through a heater. Due to its age, 15 years,
and due in part to technology advances, the pump internal components were replaced. The
efficiency was improved and future repairs made simpler. Cleaning of the digester is necessary to
The chlorine chemical tanks (2) are operated in parallel for the chemical feed. The feed is
controlled by feed regulators. For proper operation of chemical both regulators need to work
properly. Both at different times of the year failed and had to be repaired. Even though this
equipment will be replaced by the chemical conversion process, it still must be maintained until
conversion to maintain compliance.
Disinfection. The final phase of the water treatment process is disinfection (pathogen kill) and
disinfection removal. The former is done with the use of chlorine. The latter is done to remove
residual chlorine because of its negative effect on stream aquatic life. The chemical used to
remove chlorine is sulfur dioxide. The chemicals are injected with submersible 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 spare chlorine eductor
pump failed. 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. The state now has approved the plans submitted and has awarded a low interest loan to
finance the alternative disinfection and disinfection removal process. Specifications were written
up and advertised. Bids were received and approved by the state. The contract was then awarded.
Construction is to begin in early 2010. Because of the switch, eductor pumps now used for
injecting 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 risk of permit violations 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. These pumps are non-submersible. 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.
However, with the failure of the spare chlorine eductor pump, the risk of violation increased with
out a back up. Again, after some research, a standard submersible pump modified with an
injector, for a fraction of the cost of an eductor, restored the back up necessary for compliance.
unavailable parts. A new pump was budgeted. The new pump is now on line. The control panel
for the drain pump was the same age as the pump and was in poor condition. A new panel was
built and installed. It was built with stainless steel rather than carbon as the original panel was,
upgraded components and a better level control system. The panel which is located outdoors was
also built to seal better for more protection from the environment. One of the pumps associated
with this system is used for solids recycling or removal. The pump is controlled by a variable
frequency drive (VFD). This allows for more flexibility in pump usage and conserves electrical
energy. The VFD became inoperable requiring replacement. 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 had several repairs to it to keep it available for use. Each blower has an inlet and
outlet bearing. As they fail (begin to vibrate) the blower will shut down to protect from other
damage. This occurred on the blower mentioned and required replacement. Another failure with
this blower was to coupling that connects the motor shaft to the blower shaft. It was replaced.
And the motor that drives the blower failed and was replaced. The blowers are housed in a
covered but opened aired room. This allowed indirect environmental exposure that has not been
the best arrangement for protection. To improve this, the room roof was extended out to provide
better overhead protection. The sides were paneled up with metal and the front and back screened.
This addition has provided shade for the blowers that naturally run hot; another benefit of the
enclosure.
-6-
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
maintain proper operation. This is done on a 7-10 year cycle. It also provides an opportunity fro
repairs that can not be done while in operation. Digester three was taken off-line and cleaned.
While down, a pearth unit and connecting pipe were installed. The path uses 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. The pearths are located on the top of the digesters. They are accessed
daily for operation or maintenance. Access was by an attached wall vertical ladder. This made
access difficult especially if carrying items to service the pearth and also dangerous. To eliminate
this, the ladder was replaced by a set of access steps with handrails. Another byproduct of the
solids stabilization process is water. This water need to be removed to provide space for
additional solids addition to the digester. Removal of 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 replace these valves, without releasing solids into the building, was done. After all
upgrades and repairs were complete and before the digester was returned to service, the cover was
tested for integrity by floating it on water. The cover consists of a bottom, sides, and top and is
designed to float on the contents of the digester tank. It does so because the volume is constantly
changing and through this function, traps and stores methane, a byproduct of the digestion process.
The methane in turn is used by heaters to heat the solids of the digestion process. The cover at
first floated but shortly afterward sank. Apparently there were holes in the cover and the digester
could not be returned to service until repairs were made to the cover. The cover is 35 feet in
diameter and weighs approximately 80,000 pounds. A crane was brought in to lift the cover up
and out of the digester tank. This was done to make the entire cover accessible for inspection. A
metal inspection contractor was brought in. The inspection identified numerous holes in the
bottom and sides. The inspection also revealed accelerated signs of deterioration of the bottom
and sides. The top was in good shape because it remained coated over the years. However, the
sides and bottom were in constant contact with solids and could not be re-coated. Also, unless the
top is removed from the digester tank, the bottom is difficult to access and the sides are not
accessible. The cover bottom and sides could only be inspected every 7-10 years during a
cleaning cycle. During previous cycle approximately 10 years earlier, the cover bottom and side
appeared sound. The results of the metal inspection contractor ruled out patching the holes. The
next decision was to replace the metal of the bottom and side to the top that remained in good
shape or replace the entire cover. After a cost comparison analysis was performed, it showed
restoring the existing cover was more economical that a total replacement. The restoration process
went well. While the cover repair was ongoing, some digester tank repairs were being done.
When the cover sank, it broke one pipe and damaged a concrete support pillar. These repairs were
done in time before the cover was replaced on the digester tank. A crane returned the cover in
place and the digester tank refilled with water. The cover floated. Inspections revealed no sign of
cover leakage. However, during the inspection of the cover, water used for floating was going out
of the tank. The digester tank was drained and inspected. After an exhaustive search, the
inspection revealed some deterioration of the concrete walls. At one of the form seams, located
below ground level, ground water was noticed running in. This was the area where water was
exiting when the tank was full of water. Repairs to the concrete were made and the tank was
refilled with water again. This time cover and tank checked out. The unit is ready to be returned
to the digestion process. The digester tanks are attached to a control building. The control
building contains equipment, pumps and motors and hundreds of feet of piping with dozens of
valves. The building interior was originally painted in 1963 and then again in 1983. It had been
over 25 years since the last painting. The building interior was repainted. The building is color
coded to distinguish the different stages of digestion, types of chemicals, gas, water, and
electricity.
-7-
Biosolids Storage. Biosolids, waste activated and anaerobic, once stabilized are blended and
stored in a tank capable of holding one million gallons. This tank is 19 and one half feet tall and is
100 feet in diameter. The solids are mixed by 3 mixers for odor control and to prevent settling
until removed for land application. Even with mixing, over time settlement inevitably occurs and
approximately once a year the tank needs cleaning. The tank was cleaned to remove this
settlement. Cleaning also allows for access to the mixers for preventive maintenance. While
accessible, one mixer that had failed was sent off for repair. The mixer, approximately 18 years
old, had been repaired several times over the years, but was now obsolete and parts not available
gallons removed. Excessive solids from the secondary system enter a pump station by gravity
flow. From here the solids are pumped to the gravity settling tank to begin the thickening process.
The pump used for this transfer wore out and was replaced with a new one. Also the piping which
leads from the pump contains a check valve because the pumping is intermittent. During times
when the pump is off, the valve keeps solids from draining back into the pump station that would
require re-pumping of the solids. The valve wore out and was creating this problem. It was
replaced thus restoring the normal function of this pump station. After gravity thickening,
additional thickening, if required, is accomplished through a drum concentrator. Before entering
gravity or drum thickening process, bulk concentrate polymer must be diluted and mixed. This
preparation is accomplished with the use of a Dyna Blend. Sample testing determines the correct
amount of polymer to water ratio. This is done to produce the correct dosage of polymer to be
used, preventing wastage with the correct amount of water to produce correct concentration for
producing the desired floc. Therefore the Dyna Blend is a blending, mixing, and pumping piece of
equipment. From testing, the Dyna Blend can be calibrated to perform automatically. Its run time
is controlled with a float level system in the tank it supplies polymer to. The internal portion of
the pump through normal wear lost efficiency and was replaced. The Dyna Blend is also equipped
with a low flow sensor. If the polymer/water mix flow does not flow through the pump at a
normal rate, it shuts the unit down preventing accelerated wear on the pump. The flow sensor is
an electronic device. It malfunctioned and was shutting the pump down when it was not
necessary. The device was replaced, restoring proper function of the Dyna Blend. Because of the
twenty-four hour daily use of the Dyna Blend and because of long lead times for parts delivery, it
was determined for best interest that major components of the system be inventoried. Therefore,
in the event of major failure, the system can be returned to service quickly.
Lime Stabilization. Waste activated 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 mechanism broke and
had to be replaced. Lime is fed into a tank with water and mixed with a paddle wheel to keep the
mixture in solution. The gearbox that turns the paddle wheel failed and had to get replaced.
Solids once mixed with lime are transferred to holding tanks to complete the stabilization process.
Pumps used to make the transfer were worn and had to be rebuilt. In the process of removing the
pumps for repair, the mounting rail and connecting piping had deteriorated. These parts had to be
replaced before rebuilt pump could be installed and before solids transfer could occur. Once the
stabilization process is complete, solids are transferred to a storage tank and held until removed for
land application. The pumps for transfer to storage were approximately 15 years old and had been
rebuilt on several occasions. New pumps were budgeted, purchased, and installed in place of the
old pumps. Electrical wiring of this process was originally installed in a manner which made
working on equipment in this area difficult. It was also not installed in the best way to protect
equipment and was also unsafe. Because of these reasons and due to the age of the wiring,
approximately twenty years, a portion of this work areas electrical wiring was replaced.
The lime stabilization process is monitored and controlled by laboratory procedures. After
mandating this process, a used trailer was purchased to house the necessary lab equipment,
supplies, and documentation for process control and compliance. The trailer was used for a
number of years but went through much up keep and restoration. Finally scrapped, a rental trailer
was brought in for temporary use. After several years of use, funding was appropriated to build a
permanent building. It was constructed of concrete slab and metal siding. The new building
provides better consistent controlled environment which enables the laboratory procedure to run
more smoothly and accurately. Construction of this type of building should provide many years of
this building use with an easier, more accurate laboratory operation.
-8-
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 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 2009, 1,507,257 gallons of wastewater were stored. Since
The tank now equipped with five mixers did not have adequate power supply. Larger power
supply wire had to be installed. A new power panel had to be constructed. This was necessary to
be large enough to accommodate extra components as well as replace a deteriorating cabinet, 18
years old also. The new cabinet was constructed of stainless steel rather than carbon to better
withstand atmospheric elements. It was built to seal better protecting internal components. It was
also constructed with all normally used switches and buttons on the outside of the cabinet thus
negating the need to routinely open the cabinet and eliminating the possibility of accidentally
leaving the internal components exposed to the outside.
for repair. A new mixer was budgeted to replace the old mixer and return the tank to service with
3 mixers. It was determined that due to the size of the tank an additional 2 mixers should be
added. This should lengthen the time between cleanings by keeping the solids better mixed and
eliminating some non-mixed areas of the tank. Funds were budgeted and two more mixers were
purchased. Installation of the additional mixers required a second cleaning of the tank in a year’s
time. The tank was cleaned and the mixers installed. However, the tank constructed of glass lined
metal plates seated on a concrete pad was showing signs of slight leakage. While empty and
cleaned, the original erectors of the tank were contracted for repairs. The tank base and floor were
sealed and a protective coating was applied. This was done to prevent a spill and extend the useful
life of the tank.
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.
In 2009, there were no major additions of SCADA for large plant processes. However, there was
some additional work added to one of the large plant processes previously set up. The biosolids
thickening, lime storage, and solids storage had some additional signals added. Some additional
pumps and mixers and other equipment were added. This also created some additional
programming of the SCADA computer. Signal reception, on-off-alarm status, and trending of
equipment and processes were added. Due to the growth of the SCADA system, now it has
become necessary to initiate a scheduled preventative maintenance program to ensure proper
operation and prompt repairs.
Solids removed from this tank for land application is done with a gallery station equipped with
pipe, valves, and pump. This same station is used to return stored wastewater to the plant.
Therefore double duty is depended upon this pump. If the pump fails during solids or wastewater
removal, the process is shut down for lengthy periods. This could cause problems for whichever
process is on going. To eliminate this problem, this station was fitted with additional piping,
valves, and a second pump. One pump is dedicated to solids removal and the other for wastewater
removal. However, if one pump should fail, new pipe and valving allows for switching to the
other pump until the damaged pump is repaired. This now eliminates lengthy problematic
downtime. Due to the new valving arrangement, new cover plates were installed. The old carbon
steel plates were replaced with stainless. New holes were cut into the plate making ail valves
accessible with valve handles. New valve stems were fabricated for the valves making a better fit
for the valve handles. This provides better operation of the valves.
-9-
Since purchasing the land, investment improvements continued in 2009. Improvements have been
going on for nearly six years. Improvements this year included adding more rock to the access
setup in 2000, 37,875,809 gallons of wastewater have been prevented from spilling. At the
average flow of 4.1 MGD in 2009, this would be 9.2 days of flow.
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 2009, there were no power interruptions
resulting in the use of the back-up generator for power supply.
The emergency generator is also used to curtail. The District is under contract with Dominion
Power. From May 16lh through September 30th (summer curtailment) and from December Is1
through March 31s1 (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 requests 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 2009 the
wastewater plant was called to run 16 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.
The biosolids land application program permitted by the Environmental Protection Agency (EPA)
ran well in 2009. In the required annual report to North Carolina division of Water Quality
(NCDWQ) and the (EPA), there were no deficiencies or spills. In 2009 there were 216 lime
stabilization events at 12750 gallons per event for a total of 2,754,000 gallons. This is 59 % of the
days in a year. The anaerobic digestion process produced an additional 178,500 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
tum 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, 2,966,100 gallons of stabilized biosolids
were safely applied to area lands, consisting of 11 fields and 349.9 acres, for beneficial reuse.
This included the use of two different farms. Cost of this application process was approximately
$94,000. Cost of treatment to stabilize solids is separate. Land that grew fescue, Bermuda, rye,
cotton, and soybeans were applied to. The amount applied in 2009 is down nearly 3.7 % 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 2009, 505,500 gallons was decanted, at savings of $15,671.
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.
- 10-
The North Carolina Division of Water Quality performed its annual inspection of the pretreatment
program on June 26, 2009. A letter of June 30, 2009 was received summarizing the inspection.
Four items were listed as findings. None were violations or recommendations.
The pretreatment annual report (PAR) was submitted to the state pretreatment unit on February 16,
2009. A letter, dated June 30, 2009, was received stating review of the PAR indicates the report in
good order and satisfied the requirements of the North Carolina Pretreatment Program.
A revision of the Emergency Response Plan was sent to the Division of Water Quality
Pretreatment, Emergency Response, and Collection Systems Unit for approval in May 2009.
After review by the Division, the Plan was approved August 11, 2009 and adopted by the District
board on August 13, 2009. A copy was sent to each industry having a user permit.
In 2009 the industrial pretreatment program had oversight of three significant industrial users.
One user has a categorical discharge pipe. Four non-significant 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 2009 there were no significant industrial users in significant non-compliance; a
status based on the number and types of violations of a permit. There were six notices of violation
sent for permit violations.
road between the main paved road and the application field. The road is still fairly new and is still
settling in areas. More rain and heavy tanker trucks accelerated this need along with a logging
operation nearby which used part of the access road. The access road is approximately 'A mile
long of which 100% is rocked. By choice, the District did not apply biosolids to its fields in 2009.
Therefore, no nutrients were applied through this process. However, to maintain establishment of
grasses, commercial grade fertilizer was applied. The District has desired and strived to develop a
model site. In an effort to achieve this, the Agricultural
Soil and Conservation Service (ASCS) was contacted. A plan was developed to accomplish this.
The ASCS provided the majority of the funding for the plan. The plan included fencing off
waterways to keep livestock out. This required the removal of some trees that were in the line of
the fenced areas. By fencing off areas, buffer zones were created. These areas were required to be
seeded in an attempt to enhance wildlife attraction. Because the fencing isolated livestock from
waterways, waterers were installed for their use. New water lines had to be installed to provide
water for the waterers. In 2009, an access of $15,000 was spent to maintain and enhance the
application site.
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 be 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.
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 points that include
plant monitoring, industrial monitoring, performance evaluation studies, septage hauling, and
collection system samples.
-11 -
The FOG ordinance allows for variance in the grease trap cleaning schedules with the completion
of a variance study. In 2009, one variance study was initiated and completed that resulted in the
granting of an extended pumping schedule for the restaurant.
Because of space constraints, two restaurants were accessed surcharges in lieu of trap installation
in 2008. One of those restaurants closed in 2009 leaving only one restaurant being surcharges in
lieu of installing a grease trap.
The laboratory submitted all required evaluation studies and received 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 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 2009, there were sixty-two restaurants in the District database. This included the opening
of three new restaurants and the closure of five. Each of the restaurants was inspected in 2009.
Updates to the database information in 2009 include updating information such as management
contact information and new restaurant information.
Inspections resulted in the issuance of two Notices to Correct. Each of these corrections was made
by the receiving restaurant in a timely manner.
Variances are also granted for inability to install an outdoor trap based on space constraints. One
variance was granted to allow the installation of indoor self-cleaning traps based on space
constraints.
Additional requirements of the program include 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. The laboratory was inspected on
July 9, 2009 and a letter of August 24, 2009 listed findings of the inspection. Each finding was
addressed to the state September 4, 2009. No violations or deficiencies were noted.
FOG public education is a requirement of the wastewater collections system permit WQCS00027.
Ongoing efforts from 2008 continued in 2009 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
District also took part in the Home Builders Association Home and Garden show that took place at
Becker Village Mall. FOG pamphlets were given out at the District’s booth. There was also other
information available for residents to view regarding FOG and the FOG Program. The
administrative staff continues to distribute a FOG ordinance package to all new Food Preparation
There was one sanitary sewer overflow that was attributed to FOG in 2009. The overflows
occurred in residential area. Educational information was dispersed to nearby residents to inform
residents of how they can help prevent FOG accumulation in the collection system that lead to
overflows. One blockage also occurred. The 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.
- 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.
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
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 and training from the
safety program, there were no loss work days in 2008 at the wastewater treatment plant.
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.
Facilities when opening a new account. The administrative staff also gives out industrial waste
surveys to each person who opens a commercial account that asks questions regarding food
preparation and grease traps. Best management Practices (BMP) posters continued to be
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 occurred in July 2001.
The Division of Water Quality conducted their annual review of the wastewater plant May 19,
2009. A comprehensive site inspection was conducted. The site inspection went well. The
evaluation report received on June 9, 2009 stated the plant was in compliance and well
maintained. There were no recommendations or corrections. Noted too was the stormwater
program. The report stated the program was implemented and compliant.
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.
Permit limit violation
2.WWTP: None
Monitoring and Reporting Violations
2009 Sanitary Sewers Overflows (SSO)
1.
2. WWTP: N/A
Bypass of Treatment Facility
- 13-
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.
01/26/2009 - Smith Church & Vine St.
04/13/2009 - Charles Cir. & South gate Dr.
06/04/2009 - 4th & Marshall St.
07/02/2009- 13th St.M/H42
11/12/2009 - M/H - 46 east of River Rd.
11/12/2009 - M/H B-24 at Starke Dr.
11/12/2009 - M/H B-46 at West 3rd & Starke Dr.
11/12/2009 - M/H Cl82 at Kapstone Paper Mill
12/09/2009 - M/H 54 at 4th & Laurel St.
C.S.: There were 9 reportable SSO in 2009.
a.
b.
c.
d.
e.
f.
g-
h.
i.
C.S.: 3
Starke Dr. 11/12/2009
1st Manhole east of River Rd. 11/12/2009
Kapstone Paper Mill Yard 11/12/2009
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):
2. WWTP:
There was one reportable bypass of the treatment facility in which wastewater reached surface
waters in 2009. It occurred on November 12,h during a heavy rain event creating high flows. 2.7”
of rain was recorded on the 12th with 3.2” recorded the previous two days for a total of 6.4” in
three days. The flow reached nearly 18 million gallons. Last years average flow was 4.1 million
gallons per day and the plants rates capacity is 8.3 million gallons per day. As a result, the plant
could not handle all of the incoming flow and approximately 663,000 gallons were spilled. As
required, the spill was reported to the Division of Water Quality (DWQ) within 24 hours by phone
and followed up with a written report within 5 days. Due to the volume of the spill being more
than 1000 gallons and greater than 15,000 gallons, the Division of Water Quality requires a press
release and a public notice. Both of these requirements were met.
1.
a.
b.
c.
1. C.S.: None
2. WWTP: None
1. C.S.: N/A
C. Description of any known environmental impact of violations.
D. Description of corrective measures taken to address violations or deficiencies.
1.
2.
- 14-
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.
Chemicals are used for disinfection and toxic chemical 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. In an attempt to further prevent a violation, a no flow alarm light
was fitted on these pumps. If flow of chemical through these pumps ceases, a visual alarm will
alert staff to repair or switch over to the other feed pump.
The disinfection system is on a contracted semiannual preventative maintenance program. It is an
attempt to ensure that the release of hazardous chemicals, chlorine and sulfur dioxide, are
prevented. Also, the automatic tank valve closures are sent off for repairs and recertification
annually. The batteries that operate these valves are replaced regularly to ensure their proper
operation in the event of a leak.
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. RRSD rehabilitated 80 vertical feet
of brick and mortar manholes throughout the year with an epoxy based mortar and finish coat to
eliminate infiltration of the collection system Plus the Roanoke Rapids Sanitary Dist. Crews
cleaned & CCTV’ed 16.5 miles of Sewerlines. MJ Price Construction cut Chockyotte Creek
Outfall and Laterals which was 8 miles. Duke’s Root Control treated 3 tenths of a mile of 8”
sewerline. KRG cleaned & TV’ed 7 tenths of a mile of 8” sewerline, making a total of 24.5 miles
between all four companies. The district had 9 reportable spills as noted in SSO section above.
The District is very active in looking for Inflow and Infiltration. During 2009, District staff
engaged in visual inspection, flow tracking, and the resulting point repairs.
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.
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 hazardous. The District has been planning to replace these dangerous
chemicals; sodium hypochlorite for chlorine and sodium bisulfate for sulfur dioxide. With
drawings complete, the District approached the state of North Carolina for a loan. The state
approved the drawings and provided a low interest loan for construction of a new chemical feed
process for converting to a safer alternative disinfection process. Upon approval, the District
sought bids from contractors to construct. Bids have been received and contract awarded. The
1. C.S.: None
2. WWTP: None
- 15-
There are various pump station alarms throughout the plant. Some are equipped with local visual
lights, some with local visual lights and audible horns or sirens, and some are even equipped with
remote SCADA alarms. In an attempt to keep functioning alarms, they are tested on a regular
basis. As more alarms are installed, they are added to the testing list.
The plant generator is capable of powering the entire plant in the event of a power loss. Without
it, spills would occur. It is on a contracted quarterly preventative maintenance program. It is also
exercised monthly by plant staff. And, the curtailment program with the main power supply
company assures further testing and exercise of the generator.
During the process of cleaning a primary digester tank, a hole was discovered below ground level.
The hole was repaired. This discovery and repair prevented digester tank contents from leaking
out and entering the ground water system.
During high flows or some maintenance repairs, influent flow can be diverted to equalization
storage tank. Once flows lower or repairs are complete, the stored water is returned to the plant
for treatment.
Primary clarifier influent lines have grease collection pits located on them. As the pits collect
grease and fill, the flow through the influent lines can be restricted, back up, and 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.
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. As valves are repaired or replaced, they are added to the exercise list.
There are several valves around the secondary system that operate backwards. What direction
normally closes a valve opens it and vice versa. The valve pedestal concrete base was stenciled to
indicate correct operation directions. However, the raised lettering on the metal valve handle
remained incorrect. Valve placement in the correct position may have contributed to the 2009
spill. To remedy the situation, the lettering on the valve handle was ground off and the correct
positioning indicating arrows stenciled on. Also, the pedestal base was re-stenciled to be more
obvious.
The Fat, Oil, and Grease (FOG) program continues to be a useful tool for the prevention of spills.
A pretreatment technician oversees and implements the program. The technician inspects
restaurants to ensure grease trap maintenance. Best Management Practices for the control of
grease entrance into the collection system is also conveyed. Part of the FOG program is public
A 500 gallon 25% liquid caustic tank is housed at the effluent. It is used on occasion to maintain
pH levels above 6 as permit required. Liquid caustic is highly corrosive and the housing it is
presently in is inadequate containment. As part of the upcoming disinfection conversion
construction project, the liquid caustic will be housed in location with adequate containment.
Stabilized biosolids are stored in a million gallon tank while awaiting land application. During the
year some slight leakage was discovered at the base of the tank where the metal plates join the
concrete base. The tank was cleaned out and the tank supplier and installer were called in for
repairs. The bottom ring of metal plates and the outer portion of the concrete base were coated
with a protective sealer. The tank was returned to service with no apparent leaks.
Identifying and eliminating inflow and infiltration (I&I) is an on-going and difficult task. It is
important to stop or minimize to take unnecessary flows off of the treatment plant. However, it is
also important to address because excess I&I can “dilute” incoming waste. Diluted wastewater
makes it more difficult to meet percent removal requirements (85%) of the plants permit. I&I can
also hydraulically overload treatment processes making it harder to meet permit limits. In 2009,
more areas were identified and addressed to help resolve this problem.
state also approved the contractor. Construction will begin in a few months and plans are to
complete a few months thereafter.
III.NOTIFICATION
IV.CERTIFICATION
- 16-
A. 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.
The plant stormwater drains are blocked and gated to help control of undesirable runoff from the
plant site. The initial design protruded out into the road. The ones in curves on the plant site have
been struck and broken on several occasions. A new design has now been built for drains in the
curves which do not protrude out into the road.
As part of the SPPP, a no longer used and abandoned 7000 gallon sulfuric acid tank was removed.
The tank was deteriorating. Acid had previously been removed. It was used by an agricultural
processing company. However, a precipitant of sludge remained in the tank. A hazardous waste
recovery company was hired to remove the sludge for proper disposal. Also, to prepare the tank
for disposal, it was washed out. The water was recovered for proper disposal as well. The tank
was demolished and cut up for metal recycling.
There was an abandoned diesel tank on site in the same above referenced condition. The same
company cleaned and removed hazardous chemical and prepped it for demolition. It was cut up
for metal recycling.
education. The technician is required to incorporate all users of the collection system. This is
accomplished through door hangers, bill inserts, poster distribution, advertisements, public service
announcement and public displays.
The Stormwater Pollution Prevention Plan (SPPP) is a valuable tool in identifying deficiencies. It
incorporates annual awareness and training to all plant personnel. The plan allows for scheduled
identification of deficiencies before they become problems.
Reduce
Recycle
Satisfy
Develop
R. Danieley Brown, PE
Chief Executive Officer
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.
Roanoke Rapids Sanitary District
February 26,2010
Re:
Dear Sir:
Very truly yours,
Enclosures
Cc:
c ■J.xuncits aJ K9inj>fdb'n>i rciird.W.qs f«.’rf«aijr<e liptn lu dx
North Carolina Division of Water Quality
NPDES Section
1617 Mail Service Center
Raleigh, N.C. 27699-1617
If these documents should be provided to additional DWQ personnel; or if additional
information is required, please contact me.
Gregg Camp
Charles Turner
File
DENR-WATER QUALfTY
?OINT SOURCE BRANCH
2009 System Performance Annual Report
NPDES //NC0024201
NPDES #WQC00027
NCG110000
Page:
1/1
Enclosed please find tluee (3) copies of the District’s System Performance Annual Report.
This report is submitted to meet the requirements of the NCDENR/DWQ policy to promote
public oversight of system performance for reduction and elimination of sanitary sewer
overflows (SSO’s) from wastewater treatment works and sewer collection systems.
j MAR 012010
CERTIFIED MAIL
RETURN RECEIPT REQUESTED
P.O. Box 308
1000 Jackson Street
Roanoke Rapids, iNC 27870
[phone]
Fax: [phone]
www.irsd.org
4®_
R. Danieley Brown, P.E.
Chief Executive Officer
re
Time: I ? 8
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Phone Number
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NCDENR-DWQ-RRO
Surface Water Protection
Meeting Attendance Roster
Date:
SubjectJ^Kt^moLe
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_________________________
March 29, 2010
Dear Mr. Brown :
cc:
You should review this report; take actions or provide responses as indicated and then file
for your records. If you have any questions please contact me at [phone] or via e-mail
[e-mail].
Beverly Eaves Perdue
Governor
Subject: Initial Interim Inspection
Roanoke Rapids SD [Halifax]
WWTP Sodium Hypochlorite System
Project No. CS 370 449-04
Mr. R. Daniel Brown, PE
Roanoke Rapids Sanitary District
PO Box 308
Roanoke Rapids, North Carolina 27870
Hunter Carson, PE, Arcadis
Danny Smith, Raleigh Regional DWQ Office
CIG - Mark Hubbard, PE
SRF
HCDENR
North Carolina Department of Environment and Natural Resources
Division of Water Quality
Coleen H. Sullins
Director
Dee Freeman
Secretary
p k)Zoo2^37
The Construction Inspection Group (CIG) of the Construction Grants and Loans Section
performed its first interim inspection for the state and federally funded portion of subject project at
10:30 am on Friday March 12, 2010. The meeting also allowed CG&L the opportunity to present
and discuss items normally presented at the Pre-construction meeting. CG&L did not attend that
meeting on January 21. This interim inspection was conducted in conjunction with the monthly
progress meeting normally scheduled for the 2nd Friday each month. Location of the Progress
meeting was and will continue to be at the WWTP located on Aquaduct Rd. Contract completion
date is December 3, 2010.
Smcerely, . , I /
Gerald W. Horton, PE
Environmental Engineer
Construction Inspection Group
FASHAREXProject ManagemEnt BrandiXGrtnip - Constructian InspectionXPnjjects (Active)XARRA (SIIMULUS) PrujectsMavlorsvillg ARRAgw^lartnsp,ltP02J'2fldanokeRapids.dnc
Construction Grants & Loans Section
1633 Mail Service Center Raleigh NC 27699-1633 One
Phone: [phone] / FAX: [phone] / Internet: www.nccgl.net NorthCarolina
An Equal Opportunity/Affirmative Action Employer Naturally
o
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construct and install instrumentation and controls,
demolition and modifications to existing building converting it to sodium­
bisulphite building,
construct hypochlorite building to house related facilities,
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;
dechlorination system consisting of a
■ 4,470 gallon bulk sodium bisulphite storage tank and
■ two (2) 3 GPH metering feed pumps;
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.
Page 2 of 7
Interim Inspection of
March 12,2010
Total
$ 901.000
Roanoke Rapids Sanita^^>istrict
WWTP Sodium Hypochlorite System
CS 370 449-04
GENERAL CONCERNS / RECOMMENDATIONS / ACTION ITEMS -Please note UPDATES
on Comments and Concerns noted in previous progress meetings (for reference) are italicized.
1. At end of today's meeting CG&L presented items that would have been discussed at the
Preconstruction meeting had CG&L attended that meeting. Those items are contained in the
remainder of this first report.
2. CG&L requests construction schedule be provided at next meeting.
3. Owner and Engineer are requested to have a submittal log available for review at next and all
subsequent meetings until all submittals have been approved.
4. CG&L requests Inspection logs be available for review next meeting and at all subsequent
meetings.
5. Please have record drawing (as-builts) markups available for review at next meeting and all
subsequent meetings.
6. Progress meetings will be held at the WWTP, monthly for the duration of the project
on Is1 Fridays, 10:00 am.
LOAN DISBURSEMENTS
Project budget: Total Eligible Amount
Water & Waste Systems Constr., Inc. $ 901,000 $ 901.000
Contingency $ 45,000
Technical Services$ 164.800
Total Eligible Costs $ 1,110,800
Closing costs are 2% of the eligible loan amount, thus $22,216. The loan is for maximum 20
years at interest rate of 2.5 %. As of March 12, no payment reimbursements have yet been
sought.
CONTRACT:
WWTP Sodium Hypochlorite System - Water & Waste Systems Construction, Inc., (WWS)
9700 Ten-Ten Rd., Raleigh, NC 27603, Unlimited: Public Utilities, (Water Lines & Sewer
Lines), PU, (Water Pur. & Sewage Disp.) Lie. # 35745
Description of Eligible work :
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none
252 537-9132
Greg Camp 252 536-4884
Justin Blackmon 252 537-9137
Craig Williams 252 536-4884
Hunter Carson, PE 919 854-1282
Billy Clinard 919 625-8864
Gerald W. Horton, PE 919 715-6219
Pre-Construction Items normally presented follows:
Arcadis
hunter.carson @ aarcadis-us.com
Authorized Representatives:
Loan or Grant Recipient:
State:
Consulting Engineer:
Roanoke Rapids San. Dist., Director
[e-mail]
Roanoke Rapids San. Dist.
[e-mail]
Roanoke Rapids San. Dist.
[e-mail]
Roanoke Rapids San. Dist., Supv.
[e-mail]
Water & Waste Systems Constr., Inc.,
[e-mail]
NC Construction Grants & Loans
[e-mail]
List of Attendees:
Dan Brown, PE
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Interim Inspection of
March 12, 2010
CONSTRUCTION INSPECTION
Observations of WWS construction and progress:
1. mobilized
2. installed erosion control
3. began excavation
CHANGE ORDER UPDATE -
RFPs Status - none pending
RFIs Status - none pending
Project Schedule - WWS needs to provide Construction Schedule
Signs - ARRA signs have been erected and information for OSHA, wage rates etc. are posted
SUBMITTAL Status- Owner and Engineer are requested to have a submittal log available for
review at next meeting.
Inspectors logsAVork Orders - CG&L requests these be available for review at all meetings.
As-builts or Record Drawings - were not reviewed. Please have these available for review at
next meeting and all subsequent meetings.
Roanoke Rapids Sanitary District
WWTP Sodium Hypochlorite SystUP
CS 370 449-04
Daniel Brown, Roanoke Rapids Sanitary District
Mark Hubbard. PE, Gerald Horton, PE, NC-DENR, DWQ, CG&L
Hunter Carson. PE, Arcadis, 801 Corporate Center Dr., Suite 300,
Raleigh, NC 27607
Construction Observer Inspector: Justin Blackmon, Roanoke Rapids San. Disk, Constr. Obsvr.
Date and Time of next Progress meeting: Friday April 9 10:00 am at WWTP
1.
Davis Bacon interview(s) status and review Certified payroll records.
Buy American documentation,
files and status of shop drawings, submittals,
inspector's field reports,
status of record (as-built) drawings,
status of: Requests for Information (RFIs), Requests for Proposals (RFPs)
revised construction schedules,
records of testing of materials, soils, concrete, equipment, and
Page 4 of 7
Interim Inspection of
March 12, 2010
Change Orders (COs)
DWQ “approval” of change orders means the State determines the Grant or Loan eligibility
thereof. The Loan or Grant Recipient (Owner) should notify DWQ prior to commencement of any
change order work, which may change the scope of the project, except for emergency situations.
Approval of each change order is the responsibility of the Owner and Contractor. Records of COs
should be available for review at any time and CG&L requires being provided one original of all
Role Of The Construction Inspection Group (CIG)
1. Attend progress meetings and perform periodic inspections of the project.
2. Review COs for necessity and reasonableness to determine eligibility for loan or grant
funding.
3. Purpose and objectives of inspections:
a. To ensure that the overall objectives of the loan or grant are realized.
b. To monitor administration of the loan and/or grant to monitor that the project is
executed in accordance with State regulations and loan and/or grant conditions.
c. To ensure contract compliance and construction in accordance with NC DENR approved
contract documents, plans and specifications and loan or grant agreement.
d. To advise and offer assistance to the loan and/or grant Recipient.
Roanoke Rapids Sanital^^istrict
WWTP Sodium Hypochlorite System
CS 370 449-04
CIG Inspections
Prior notice will be given; however, unannounced inspections may also be conducted.
2. Inspections will be concerned with administrative matters and construction matters/activities.
3. During inspections, CIG may wish to review, observe and/or discuss:
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o pending or executed change orders for completeness, accuracy and whether justified and if
reasonable.
4. The Division of Water Quality (DWQ) requests that all equipment and materials on job site be
properly stored, stockpiled, and protected. Improper storage of materials and equipment may
result in recommendation to reduce reimbursement amount. The job site(s) shall be maintained
in an acceptable manner.
5. Safe working conditions should be maintained at all times. CIG will discuss potential or
apparent safety violations, which may be life endangering or threatening of serious injury. If
warranted or deemed necessary, CIG will take prompt action including notifying State and
OSHA regional representatives of any noted conditions. It remains the Contractor’s sole
responsibility to maintain safe working conditions and activities.
6. Results of the inspection will be discussed at the job site during or upon completion of the
inspection.
7. Formal copies of the inspection report will be sent to the loan and or grant Recipient, the
Engineer and only to other parties, if so requested.
8. CIG asks to be notified when the Engineer or Owner plan to schedule a pre-final and/or the
final inspection(s). CG&L requests a copy of punch list(s). In order to close out the project
CG&L must conduct a final inspection.
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executed COs and supporting information so CG&L may determine the CO7s eligibility for the
loan or grant. However, approval of COs by CG&L is not necessary on STAG projects. CG&L
does however request a copy of each CO on STAG projects. Owner is advised that occasionally
EPA requests the State review STAG CO(s) for efficacy and to determine if justified.
Generally, at a minimum one final adjusting change order will be necessary. Also, no
reimbursement payments can be made for bid items where the installed quantity exceeds bid
quantity until a change order has been "approved" by CG&L for the additional quantity(ies).
Also please provide attached change order checklist with all necessary documentation with each
change order.
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Interim Inspection of
March 12, 2010
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Roanoke Rapids Sanitary District .
WWTP Sodium Hypochlorite Systi
CS 370 449-04
Owner Payment Request
Before first reimbursement request will be processed, the Owner must provide NC CG&L
executed engineering contiact(s) and executed Construction contract(s). It is recommended
that prior to first reimbursement request, the submitter call and talk to Ms. Leslie Rogers in
CG&L accounting section at [phone], which may help to avoid submittal enors.
Submittal forms may be found at CG&L's website: www.nccgl.net.
Owner shall provide the NC CG&L inspector with Schedule(s) of Values (SOV) and
Construction (Progress) Schedule for each construction contract. SO Vs should correlate with
Bid items or construction costs or Schedule of Values breakdown, as applicable. The
Contractor’s pay request should coincide with the items on the bid form or approved schedule
of values. Providing the SOV to CG&L in electronic format, excel or other spreadsheet would
be appreciated.
Owner shall expend all of the requisitioned funds for the purpose of paying the costs of the
project within three (3) banking days following receipt of the funds from the State.
Owner should be aware of the following payment milestones:
Before first reimbursement can be made Contract Documents must be approved. Contract
document(s) with original signatures shall be provided to CG&L. contracts documents include
the entire set of specifications with the AGREEMENT included.
Owner shall submit or have submitted Capital Projects Ordinance (CPO)
Prior to 90% Disbursement - All tax must be reported and O&Ms (if required) must be
submitted and approved..
Before final reimbursement - Engineer’s Certification of Completion must be received.
Loan or Grant Agreement/Amendments and all conditions placed on them, if applicable, must
be satisfied prior to reimbursements.
Do submit / report sales tax with each pay request. The sales tax report should indicate the time
period that is covered. The reimbursement amount will be reduced by the sales tax amount at the
90% milestone. The sales tax is included in the Owner’s loan or grant amount. Therefore, the
Owner should be prepared to cover this amount until they receive a disbursement or
reimbursement. If the contractor makes no purchases and has no sales tax to report for the period.
Recipient’s (Owner) And Engineer’s Responsibility
1. The Owner and Engineer should become familiar with their responsibilities as defined in
the Code of Federal Regulations Part 40 CFR.
2. STAG grant conditions must be met and Ioan or grant objectives achieved.
3. For STAG (State and Tribal Assistance Grant) projects, the Owner shall submit Quarterly
Project Progress reports and separate Quarterly MBE/WBE reports. Progress Project
Quarterly report format and mailing information is attached if this is a STAG project. An
electronic version is available on CG&L's web site. Project Progress Quarterly reports are to
be submitted to CG&L, however the MBE/WBE quarterly reports are to be submitted directly
to EPA as agreed to by Owner upon acceptance of the STAG Grant offer. Owner should refer
to that documentation.
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< END Preconstruction Meeting Report >
regardless, the sales tax report should be submitted and indicate “No sales tax to report this
period.”
7. If requesting reimbursement / payment for materials stored on site, invoice(s) must be provided
to document material cost. Such materials shall be stored safely and securely on site or in a
bonded location(s). An affidavit from the Engineer may be requested by CG&L for items
stored at a bonded location.
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Interim Inspection of
March 12,2010
Environmental Protection EXPECTATIONS
The Owner is advised that the protection of the environment is a loan or grant requirement. It is
for Owner, Contractor(s), Engineer and other participating entities to comply with all
environmental pollution control programs established by Local jurisdiction, the State, or the EPA.
1. Continued proper conveyance and treatment of Owner's wastewater during
construction.
2. Proper disposal of all solid and hazardous wastes encountered or generated as part of the
project.
Notifying the NC Division of Water Quality (DWQ) field office in
Raleigh, NC, telephone: [phone] to report an oil spill, bypass of sewage or other
environmental emergency caused by any party. The responsible party should take the
initiative to report the matter promptly and to initiate containment and cleanup activities.
Submission of, adherence to, and compliance with the erosion and sedimentation control
plan approved by the applicable State or local agency.
Protection of existing trees, shrubs, and grass, practice effective measures for dust control
of haul roads, excavation areas, work areas, and borrow areas and restoration of all such
areas.
Because this is an environmental project, it is expected that the Contractor(s) and sub
contractors collect and properly dispose of litter, trash and debris generated by workmen on
the project or on the site and along routes of the work.
Roanoke Rapids Sanita^wstrict
WWTP Sodium Hypochlorite System
CS 370 449-04
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Owner
Project Name
Project No.
Change Order No.
Contract No.
Contractor
The following checklist must be completed and all information must be submitted prior to
approval. Incomplete submittals will not be reviewed. If CG&L requests additional information
and it is not received within 14 calendar days, CG&L may return all Change order information.
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NC CONSTRUCTION GRANTS & LOANS
CHANGE ORDER CHECKLIST
Roanoke Rapids Sanitary District
WWTP Sodium Hypochlorite Syst^^
CS 370 449-04
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interim Inspection of
March 12,2010
Change Order Documents
□One properly executed change order (original signatures) shall be submitted. CG&L does
not approve change orders, it determines eligibility. Justification, cost basis, time
adjustments and other relevant information shall be included in order for CG&L to make a
determination as to eligibility. All signatories must be clearly identified with title and
printed name in proximity of original signature.
For a preliminary change order review; all supporting documentation must be included;
Federal and/or State Project number(s) shown on the change order;
Clear description of each change;
Detailed justification to identify the need for each change;
Justification and documentation for any contract time extensions (Time extensions for weather
should be for above-average precipitation. The average number of days with precipitation
greater than 0.10" for each month can be obtained from NOAA Report No. 20);
Copies of new or revised contract drawings and/or specifications for the change may be
necessary. Engineer and Owner are advised that certain changes (change in scope or
significant changes) may require a modification to the Permit or the Authorization to
Construct.
Cost Documentation
Each of the following items should be considered when determining what information and
documentation to submit with each change order:
Revised drawings for change, if applicable;
Engineer’s independent cost estimate;
Justification for change and who initiated change;
Contractor's proposal or detailed cost breakdown for labor, material, equipment, tax,
overhead, and profit. It is recommended that for unit price and quantity change orders that
an electronic spreadsheet be provided. This may be relayed via email;
Copies of suppliers’ invoices for major items, if applicable;
Memorandum of Negotiation which documents the negotiation process and the basis for
the final negotiated settlement.