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Home My WebLink AboutNC0025453_Historical information_20221231December 2, 2022 Dear Mr. Cappola: 1. The current permit became effective March 1, 2022 and will expire March 31, 2024. ^-DEQ Department of Environmental QuaHty^k NORTH CAROLINA Environmental Quality Subject: Compliance Evaluation Inspection Sam’s Branch WRF NPDES Permit: NC0025453 Johnston County ROY COOPER Covernor EL1ZABETH S. BISER Secretary RICHARD E. ROGERS, JR. Director Richard Cappola Jr., Interim Town Manager Town of Clayton PO Box 879 Clayton, NC 27520 Mitch Hayes of the Raleigh Regional Office conducted the subject inspection on November 22, 2022. The assistance of Bill Simpson WW-4 Operator in Responsible Charge (ORC) and Michael Ratley, with this inspection was greatly appreciated. Please find attached to this letter the Basinwide Information Management System (BIMS) check list summarizing the inspection. Below is list of findings developed from the inspection and review of the permit: 2. The facility is currently permitted to discharge 2.5 MOD of treated wastewater to the Neuse River. An amended agreement with the City of Raleigh to increase the amount of wastewater to send to the Neuse River Resource Recovery Facility from 1.0 MOD to 1.75 MOD effective December 2021. The Town of Clayton also has an agreement with Johnston County to send 1.4 MOD of wastewater to Central Johnston County WWTP. 3. The 2.5 MOD water reclamation facility consists of the following units: influent head works with a biofilter odor control system; mechanical and automatic bar screens; a vortex type grit removal system; influent pump station with three (3) 60-Hp dry pit submersible pumps and one (1) 40-Hp pump; 9-inch Parshall flume with ultrasonic flow meter; a 214,500 gallon anaerobic selector tank in front of the first stage anoxic tank; a 300,000 gallon first stage anoxic tank in front of oxidation basin # 2; two (2) - oxidation basins; a 200,000 gallon first stage anoxic tank in front of oxidation basin # 1; three (3) secondary clarifiers; Return Activated Sludge pump station; two (2) shallow bed DAVCO traveling bridge type tertiary filters; UV disinfection, two banks, with back-up chlorination / dechlorination; effluent pump station; one (1) 90,000 gallon aerated digester/sludge stabilization tank; two (2) - 360,000 gallon aerated sludge holding tanks; sludge loading station; a sludge thickening building containing two (2) rotary drum thickeners with polymer flocculation; sludge transfer pump station; sludge drying beds; North Carolina Department of Environmental Quality | Division of Water Resources Raleigh Regional Office I 3800 Barrett Drive I Raleigh, North Carolina 27609 919.791.4200 /?€ Ce ii/e. 6. 7.last completed September 2021. The permit 9. 10. Effluent and Influent flow meters were I May 12, 2022, and is calibrated annually. The Annual Pollutant Scan (APS) was 1 requires the APS to be completed before the end of this year, *2022. last calibrated by Chadwick Instrumentation on Results for Toxicity testing for the period September 2021 to June 2022 showed compliance with the permit. 11. Discharge Monitoring Reports (DMR’s) for the period September 2021 through September 2022 were reviewed for compliance with permit limits and monitoring requirements. A Notice of Violation for exceeding Quarterly Average for Total Phosphorus for September 2022 DMR. This violation will be addressed under a separate correspondence. There were no other monitoring or limit violations. 8. The laboratory was checked in a cursory manner. Sam’s Branch WRF laboratory, certification number 348, analyzes BOD, TSS, fecal coliform, Phosphorus, Nitrate, COD and is field certified for TRC, pH, temperature, DO, specific conductance. Environment 1, certification number 10, Cameron Testing, certification number 654, and Meritech Labs, certification number 027, analyses all other parameters. 4. At the time of inspection, all units listed in the permit were observed and no negative issues were found. The biofilter odor control system appeared to be operating normally. The automatic and manual bar screens and vortex grit removal system were functioning normally. The number 1 aerated sludge holding tank was approximately 80% full. The number 2 aerated sludge holding tank was approximately 40% full. Sludge was being off-loaded into a truck. Thickened sludge is taken to Beulaville, NC for land application. Aerators in sludge holding tank number 1 and 2 were operational. Influent in the two oxidation basins was medium brown in color with very little foam in oxidation ditch #1. Foam covered about 20% of the surface area in ditch #2. Covers have been placed over the anaerobic selector to prevent odor. The #1 secondary clarifier was not in service. Effluent appeared clear flowing off the weirs in secondary clarifiers 2 and 3. Effluent in the wet well at the tertiary filters appeared clear with no foam. The sludge drying beds had little sludge in them. 5. Permit annual fee for the period July 1, 2022 to June 30, 2023 was due July 3, 2022. Please remit the overdue amount of $3,440 as soon as possible. A-t-k'- Aac The annual performance report was last issued August 2022 and is available on the Town’s website and at the Town Hall. in-plant non-potable wa^fcystem using reclaimed treated waste^^er; a reclaimed water pump station and transmission force main to the Pine Hollow Golf Course and two (2) on-site generators and one portable generator to provide back-up power. ET NOrth Car0l‘na of Environmental Quality | Division of Water Resources 512 North Salisbury Street | 1611 Mail Service Center I Raleigh, North Carolina 27699-1611 919.707.9000 Sincerely, invoice North Carolina Department of Environmental Quality | Division of Water Resources 512 North Salisbury Street | 1611 Mail Service Center | Raleigh, North Carolina 27699-1611 919.707.9000 Vanessa E. Manuel, Assistant Regional Supervisor Water Quality Regional Operations Section Raleigh Regional Office NCDEQ Attachment: Annual -Fee Laserfiche Oeuartment cf Environments! 12. Commercial ^^results, chain of custody records, ant^^nch sheets were compared with data submitted on the DMR for September 2022. Results for Toxicity testing percentage was inadvertently listed as 0.2% instead of 2.0%. A revised DMR will be submitted. I would like to thank Bill Simpson and Michael Ratley with this inspection. If there are any questions about the inspection or this letter, please contact Mitch Hayes at 919.791.4261 or at mitch.hayes@ncdenr.gov . EPA Section A: National Data System Coding (i.e., PCS) yr/mo/dayNPDES I11 22/11/22NC0025453 6 72 Section B: Facility Data Entry Time/Date Permit Effective Date 21/02/0110:00AM 22/11/22 Sam's Branch WRF Exit Time/Date 22/11/2211:30AM Name(s) of Onsite Representative(s)/Titles(s)/Phone and Fax Number(s)Other Facility Data Name, Address of Responsible Official/Title/Phone and Fax Number Contacted No Section C: Areas Evaluated During Inspection (Check only those areas evaluated) Section D: Summary of Finding/Comments (Attach additional sheets of narrative and checklists as necessary) (See attachment summary) DateAgency/Office/Phone and Fax NumbersName(s) and Signature(s) of Inspector(s) DWR/RRO WQ/919-791-4200/ DateAgency/Office/Phone and Fax Numbers iPage# B Permit | Sludge Handling Dispos H Laboratory Name and Location of Facility Inspected (For Industrial Users discharging to POTW, also include POTW name and NPDES oermit Number) 1000 Durham St Clayton NC 27520 Flow Measurement Facility Site Review ■ Records/Reports ■ Self-Monitoring Progran K Compliance Schedules | Effluent/Receiving Wate Form Approved. OMB No. 2040-0057 Approval expires 8-31-98 Permit Expiration Date 24/03/31 Steven Biggs,PO Box 879 Clayton NC 275280879/Town Manager/919-553-5866/9195531541 /// William R Simpson/ORC/919-553-1535/ William R Simpson/Superintendent WRF/919-553-1355 /9195538919 United States Environmental Protection Agenc^^^ Washington, D.C. 20460 Water Compliance Inspection Report QA N Inspection Work Days 671 I Fac Type 20U12l Facility Self-Monitoring Evaluation Rating 70 [4J J17 Mitchell S Hayes Signature of Management Q A Reviewer EPA Form 3560-3 (Rev 9-94) Previous editions are obsolete. Inspector 19L2J -Reserved------------------- 75l I I I I I I I80 3l 73LLI74 Transaction Code 1 N 2LJ 2i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i i r Inspection Type 18lc] Bl 71 u 1(Cont.) J17 2Page# NPDES NC0025453 yr/mo/day 22/11/22 Section D: The current permit became effective March 1,2022 and will expire March 31, 2024. The facility is currently permitted to discharge 2.5 MOD of treated wastewater to the Neuse River. An amended agreement with the City of Raleigh to increase the amount of wastewater to send to the Neuse River Resource Recovery Facility from 1.0 MGD to 1.75 MGD effective December 2021. The Town of Clayton also has an agreement with Johnston County to send 1.4 MGD of wastewater to Central Johnston County WWTP. 12lI11 Inspection Type 18[c] Summary of Finding/Comments (Attach additional sheets of narrative and checklists as necessary) Results for Toxicity testing for the period September 2021 to June 2022 showed compliance with the permit. The 2.5 MGD water reclamation facility consists of the following units: influent head works with a biofilter odor control system; mechanical and automatic bar screens; a vortex type grit removal system; influent pump station with three (3) 60-Hp dry pit submersible pumps and one (1) 40-Hp pump; 9-inch Parshall flume with ultrasonic flow meter; a 214,500 gallon anaerobic selector tank in front of the first stage anoxic tank; a 300,000 gallon first stage anoxic tank in front of oxidation basin # 2; two (2) - oxidation basins; a 200,000 gallon first stage anoxic tank in front of oxidation basin # 1; three (3) secondary clarifiers; Return Activated Sludge pump station; two (2) shallow bed DAVCO traveling bridge type tertiary filters; UV disinfection, two banks, with back-up chlorination / dechlorination; effluent pump station; one (1) 90,000 gallon aerated digester/sludge stabilization tank; two (2) - 360,000 gallon aerated sludge holding tanks; sludge loading station; a sludge thickening building containing two (2) rotary drum thickeners with polymer flocculation; sludge transfer pump station; sludge drying beds; in-plant non-potable water system using reclaimed treated wastewater; a reclaimed water pump station and transmission force main to the Pine Hollow Golf Course and two (2) on-site generators and one portable generator to provide back-up power. At the time of inspection, all units listed in the permit were observed and no negative issues were found. The biofilter odor control system appeared to be operating normally. The automatic and manual bar screens and vortex grit removal system were functioning normally. The number 1 aerated sludge holding tank was approximately 80% full. The number 2 aerated sludge holding tank was approximately 40% full. Sludge was being off-loaded into a truck. Thickened sludge is taken to Beulaville, NC for land application. Aerators in sludge holding tank number 1 and 2 were operational. Influent in the two oxidation basins was medium brown in color with very little foam in oxidation ditch #1. Foam covered about 20% of the surface area in ditch #2. Covers have been placed over the anaerobic selector to prevent odor. The #1 secondary clarifier was not in service. Effluent appeared clear flowing off the weirs in secondary clarifiers 2 and 3. Effluent in the wet well at the tertiary filters appeared clear with no foam. The sludge drying beds had little sludge in them. Permit annual fee for the period July 1,2022 to June 30, 2023 was due July 3, 2022. Please remit the overdue amount of $3,440 as soon as possible. The annual performance report was last issued August 2022 and is available on the Town’s website and at the Town Hall. The Annual Pollutant Scan (APS) was last completed September 2021. The permit requires the APS to be completed before the end of this year, 2022. The laboratory was checked in a cursory manner. Sam’s Branch WRF laboratory, certification number 348, analyzes BOD, TSS, fecal coliform, Phosphorus, Nitrate, COD and is field certified for TRC, pH, temperature, DO, specific conductance. Environment 1, certification number 10, Cameron Testing, certification number 654, and Meritech Labs, certification number 027, analyses all other parameters. 3Page# Discharge Monitoring Reports (DMR's) for the period September 2021 through September 2022 were reviewed for compliance with permit limits and monitoring requirements. A Notice of Violation for exceeding Quarterly Average for Total Phosphorus for September 2022 DMR. This violation will be addressed under a separate correspondence. There were no other monitoring or limit violations. Commercial lab results, chain of custody records, and bench sheets were compared with data submitted on the DMR for September 2022. Results for Toxicity testing percentage was inadvertently listed as 0.2% instead of 2.0%. A revised DMR will be submitted. Permit: NC0025453 Owner - Facil^^Sam's Branch WRF Inspection Date: 11/22/2022 Inspection Type: Compliance Evaluation Effluent and Influent flow meters were last calibrated by Chadwick Instrumentation on May 12, 2022, and is calibrated annually. Compliance Schedules Comment: No compliance schedules. Permit Yes No NA NE Record Keeping Yes No NA NE Is a copy of the current NPDES permit available on site? 4Page# ■ ■ ■ ■ ■ ■ ■ ■ Is there a compliance schedule for this facility? Is the facility compliant with the permit and conditions for the review period? Permit: NC0025453 Inspection Date: 11/22/2022 Yes No NA NE ■ ■ ■ Owner - Facility: Sam's Branch WRF Inspection Type: Compliance Evaluation (If the present permit expires in 6 months or less). Has the permittee submitted a new application? Is the facility as described in the permit? # Are there any special conditions for the permit? Is access to the plant site restricted to the general public? Is the inspector granted access to all areas for inspection? Are records kept and maintained as required by the permit? Is all required information readily available, complete and current? Are all records maintained for 3 years (lab. reg. required 5 years)? Are analytical results consistent with data reported on DMRs? Is the chain-of-custody complete? Dates, times and location of sampling Name of individual performing the sampling Results of analysis and calibration Dates of analysis Name of person performing analyses Transported COCs Are DMRs complete: do they include all permit parameters? Has the facility submitted its annual compliance report to users and DWQ? (If the facility is = or > 5 MGD permitted flow) Do they operate 24/7 with a certified operator on each shift? Is the ORC visitation log available and current? Is the ORC certified at grade equal to or higher than the facility classification? Is the backup operator certified at one grade less or greater than the facility classification? ■ Comment: No special conditons Record Keeping Yes No NA NE Facility has copy of previous year's Annual Report on file for review? Comment: Flow Measurement ■ Influent Yes No NA NE # Is flow meter used for reporting? Is flow meter calibrated annually? Effluent flow used for reporting.Comment: Flow Measurement - Effluent Yes No NA NE Comment: All meters calibrated by Chadwick May 12, 2022. Aerobic Digester Yes No NA NE Is the capacity adequate? Comment: Aerobic sludge tank. Was being off-loaded into a truck at the time of inspection. Drying Beds Yes No NA NE 5Page# # Is flow meter used for reporting? Is flow meter calibrated annually? Is the flow meter operational? (If units are separated) Does the chart recorder match the flow meter? Is the flow meter operational? (If units are separated) Does the chart recorder match the flow meter? # Is the odor acceptable? # Is tankage available for properly waste sludge? Is the mixing adequate? Is the site free of excessive foaming in the tank? ■ ■ ■ ■ ■ ■ ■ Is there adequate drying bed space? Is the sludge distribution on drying beds appropriate? Are the drying beds free of vegetation? # Is the site free of dry sludge remaining in beds? Is the site free of stockpiled sludge? Is the filtrate from sludge drying beds returned to the front of the plant? # Is the sludge disposed of through county landfill? ■ ■ ■ ■ Permit: NC0025453 Inspection Date: 11/22/2022 Owner - Faci^^^ Sam s Branch WRF Inspection Type: Compliance Evaluation Drying Beds Yes No NA NE Solids Handling Equipment Yes No NA NE Comment: Influent Sampling Yes No NA NE Is proper volume collected? Comment: Effluent Sampling Yes No NA NE 6Page# # Is the sludge land applied? (Vacuum filters) Is polymer mixing adequate? # Is composite sampling flow proportional? Is sample collected above side streams? Is the tubing clean? # Is proper temperature set for sample storage (kept at less than or equal to 6.0 degrees Celsius)? Is sampling performed according to the permit? ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ Is the equipment operational? Is the chemical feed equipment operational? Is storage adequate? Is the site free of high level of solids in filtrate from filter presses or vacuum filters? Is the site free of sludge buildup on belts and/or rollers of filter press? Is the site free of excessive moisture in belt filter press sludge cake? The facility has an approved sludge management plan? Permit: NC0025453 Inspection Date: 11/22/2022 ■ ■ ■ ■ Owner - Facility: Sam's Branch WRF Inspection Type: Compliance Evaluation Is composite sampling flow proportional? Is sample collected below all treatment units? Is proper volume collected? Is the tubing clean? # Is proper temperature set for sample storage (kept at less than or equal to 6.0 degrees Celsius)? Is the facility sampling performed as required by the permit (frequency, sampling type representative)? Comment: 3 sludge drying beds in use. Little to no sludge in drying bed