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Home My WebLink AboutNC0074268_Compliance Sampling Inspection_20160926k PAT MCCRORY Governor �d x. w DONALD R. VAN DER VAART ' Secrzrary WaterResourc�s� S. JAY ZIMMERMAN . ENVIR6NMENTAL QUALITY %>irennr September 26, 2016 RECEIVEDINGDEQ1 WR Ms. Stephanie Scheringer, Division Manager OCT 0 4 2016 Two Rivers Utilities Water Quality P.O. Box 1748 -Section Permitting Gastonia, NC 28053 Subject: Compliance Sampling Inspection Crowders Creek WWTP NPDES Permit No. NCO074268 Gaston County Dear Ms. Scheringer: Enclosed is a copy of the Compliance Sampling Inspection for the inspection conducted at the subject facility September 20,2016 by Ori Tuvia. Kevin Morgan's and Charlie Graham's cooperation during the site visit was much appreciated. Please advise the staff involved with this , NPDES Permit by forwarding a copy of the enclosed report. Split samples were taken during the inspection. Results of the split sampling will be sent at a later date. The report should be self-explanatory; however, should you have any questions concerning this report, please do not hesitate to contact Ori Tuvia at (704) 235-2190,,or at ori.tuvia@ncdenr.gov. Cc: NPDES Unit MRO Files Sincerely, Ori Tuvia, Environmental Engineer Mooresville Regional Office Division of Water Resources, DEQ Mooresville Regional Office Location: 610 East Center Ave., Suite 301 Mooresville, NC 28115 Phone: (704) 663-16991 Fax: (704) 663-60401 Customer Service: 1-877-623-6748 United States Environmental Protection Agency Form Approved. EPA Washington, D.C. 20460 OMB No. 2040-0057 Water Compliance Inspection Report Approval expires a-31-98 Section A: National Data System Coding (i.e., PCS) ' Transaction Code NPDES yr/nio/day Inspection Type Inspector Fac Type 2 15 1 3'1 NCO074268 I11 12 I 16/09/20 I17 181 c I 19 I G I 20I I 21111111 1111111111111111 11111111 11111111111 166 I Inspection Work Days Facility Self -Monitoring Evaluation Rating 61 QA Reserved 67 1.0 701a 1 71 Iti I 72 1 N 1 731 I 174 75III 80 l_1 LJ I I I Section B: FacilityData Name and Location of Facility Inspected (For Industrial Users discharging to POTW, also -include Entry Time/Date Permit Effective Date POTW name and NPDES hermit Number) 10:10AM 16/09/20 11/05/01 Crowders Creek WWfP 5642 S York Rd Exit Time/Date permit Expiration Date Gastonia NC 28052 12:55PM 16/09/20 15/08/31 Name(s) of Onsite Representative(s)/Titles(s)/Phone and Fax Number(s) Other Facility Data Charlie Graham/l/ Kevin Morgan Graves/ORC/704-214-9153/ Name, Address of Responsible OfficiatiTitle/Phone and Fax Number Contacted Stephanie B Scheringer,PO Box 1748 Gastonia NC 280531748/Division Manager W WT/704-866-6726/ No Section C: Areas Evaluated During Inspection (Check only those areas evaluated) Permit Flow Measurement Operations & Maintenance Records/Reports Self -Monitoring Program Sludge Handling Disposal Facility Site Review Effluent/Receiving Waters Laboratory Section D: Summary of Finding/Comments (Attach additional sheets of narrative and checklists as necessary) (See attachment summary) Name(s) and Signature(s) of Inspector(s) Agency/Office/Phone and Fax Numbers Date r Ori A Ttivia � MRO WQ/I704-663-1699! �lz 6 // Signature of Management Q A Reviewer Agency/Office/Phone and Fax Numbers Date W. Corey Basinger MRO WQ//704-235-2194/ EPA Form 3560-3 (Rev 9-94) Previous editions are obsolete. �"-r:;?A16 . Page# NPDES yr/mo/day Inspection Type 31 NU074268 12 16 9/20 17 181 Section D: Summary of Finding/Comments (Attach additional sheets of narrative and checklists as necessary) Sampling inspection (collected samples for BOD, TSS, Fecal Coliform, Nutrients and metals) I 9 Page# 2 f Permit: NCO074268 Owner -Facility: Crowders Creek WWTP Inspection Date: 09/20/2016 Inspection Type: Compliance Sampling Permit Yes No NA NE (If the present permit expires in 6 months or less). Has the permittee submitted a new 0 ❑ ❑ ❑ application? Is the facility as described in the permit? 0 ❑ ❑ ❑ # Are there any special conditions for the permit? ❑ ❑ ❑ Is access to the plant site restricted to the general public? 0 ❑ ❑ ❑ Is the inspector granted access to all areas for inspection? ❑ ❑ ❑ Comment: The Division received the permit renewal package on 3/2/2015. The subject permit expired on 8/31/2015. Record Keeping Yes No NA NE Are records kept and maintained as required by the permit? M ❑ ❑ ❑ Is all required information readily available, complete and current? ❑ ❑ ❑ Are all records maintained for 3 years (lab. reg. required 5 years)? ❑ ❑ ❑ 0 Are analytical results consistent with data reported on DMRs? M ❑ ❑ ❑ Is the chain -of -custody complete? 0 ❑ ❑ 0 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 CDCs Are MRS complete: do they include all permit parameters? ❑ ❑ ❑ Has the facility submitted its annual compliance report to users and DWQ? M ❑ ❑ ❑ (If the facility is = or > 5 MGD permitted flow) Do they operate 24/7 with a certified operator M ❑ ❑ ❑ on each shift?_ Is the ORC visitation log available and current? M ❑ ❑ ❑ Is the ORC certified, at grade equal to or higher than the facility classification? M ❑ ❑ ❑ Is the backup operator certified at one grade less or greater than the facility classification? ❑ ❑ ❑ Is a copy of the current NPDES permit available on site? ❑ ❑ ❑ Facility has copy of previous year's Annual Report on file for review? M ❑ ❑ ❑ Comment The records reviewed during the inspection were organized and well maintained. bMRs. COCs ORC lops Calibration logs and' Bench sheets were reviewed for the period October 2015 through July 2016. Laboratory Yes No NA NE • Page# 3 Permit: NCO074268 Owner-Facility: Crowders Creek WWTP Inspection Date: 09/20/2016 Inspection Type: Compliance Sampling Laboratory Yes No NA NE Are field parameters performed by certified personnel or laboratory? . M ❑ ❑ ❑ Are all other parameters(excluding field parameters) performed by a certified lab? 'M ❑ ❑ ❑ # Is the facility using a contract lab? 0 ❑ ❑ ❑ # Is proper temperature set for sample storage (kept at less than or equal to 6.0 degrees 0 ❑ ❑ ❑ Celsius)? . Incubator.(Fecal Coliform) set to 44.5 degrees Celsius+/- 0.2 degrees? ❑ ❑ ❑ M Incubator (BOD) set to 20.0 degrees Celsius +/-1.0 degrees? ❑ ❑ ❑ M Comment: Influent and effluent analyses (including field) are performed under the on-site laboratory certification #210. Meritech Labs inc., laboratory certification_ 4165, has been contracted to provide analytical support. Influent Sampling Yes' No NA NE # Is composite sampling flow proportional? M ❑ ❑ ❑ Is sample collected above side streams? 0 ❑ ❑ ❑ Is proper volume collected? 0 ❑ ❑' ❑ 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? N . ❑ ❑ , ❑ Comment: The subiect permit requires composite BOD and TSS influent sampling. Monthly aliquot' verifications are performed and documented. At the time of the inspection the influent . sampler pulled 190 ml. Effluent Sampling Yes No NA NE Is composite sampling flow proportional? N ❑ ❑ ❑ Is sample collected below all treatment units? N ❑ ❑ ❑ 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 ❑ El ❑ Celsius)? Is the facility sampling performed as required by the permit (frequency, sampling type N ❑ ❑ ❑ representative)? Comment: Upstream / Downstream Sampling Yes No NA NE Page# 4 J J Permit: NCO074268 Owner -Facility: Crowders Creek WWTP Inspection Date: 09/20/2016 Inspection Type: Compliance Sampling Upstream / Downstream Sampling Yes No NA NE Is the facility sampling performed as required by the permit (frequency, sampling type, and " N ❑ ❑ ❑ sampling location)? Comment: Operations & Maintenance Yes No NA NE Is the plant generally clean with acceptable housekeeping? ❑ ❑ ❑ Does the facility analyze process control parameters, for ex: MLSS, MCRT, Settleable M_ ❑ ❑ ❑ Solids, pH; DO, Sludge Judge, and other that are applicable? Comment: The wastewater facility appeared to be properly operated and well maintained. The ORC and staff incorporate a comprehensive process control program (including Chem-Sban'Unit) "with -all measurements being properly documented and maintained on-site.The facility is equipped with a SCADA system to assist the staff with the operation of the treatment units/processes. Selected plant alarms are also connected to a plant -wide audible -system to notify operators out in the plant of alarm conditions. Bar Screens Yes No NA NE Type of bar screen - a.Manual ❑ b.Mechanical Are the bars adequately screening debris? ❑ ❑ ❑ Is the screen free of excessiveAebris? ❑ ❑ ❑ Is disposal of screening in compliance? M. ❑ El ❑ Is the unit in good condition? ❑ ❑ ❑ Comment: Flow Measurement - Influent Yes No NA NE # Is flow meter used for reporting? ❑ EY ❑ Is flow meter calibrated annually? 0 ❑ ❑ ❑ Is the flow meter operational? ❑ ❑ ❑ (If units are separated) Does the chart recorder match the flow meter? ❑ ❑ ❑ Comment: New influent sampler installed on 7/29/206. Grit Removal Yes No NA NE . Type of grit removal a.Manual ❑ b.Mechanical Page# 5 d Permit: NC0074268 Owner -Facility: Crowders Creek WWTP Is the pump wet well free'of bypass lines or structures? ❑ Inspection Date: 09/20/2016 Inspection Type: Compliance Sampling Is the wet well free of excessive grease? N ❑ Grit Removal Yes • No NA NE Is the grit free of excessive organic matter? ❑ ❑ ❑ ❑ Is the grit free of excessive odor? ❑ ❑ M ❑ # Is disposal of grit in compliance?. ❑ ❑ 0 ❑ Comment: At the time of the inspection the grit removal was out for repairs. Pump Station - Influent Yes No NA NE Is the pump wet well free'of bypass lines or structures? ❑ Q ❑ Is the wet well free of excessive grease? N ❑ ❑ ❑ Are all pumps present? 0 ❑ ❑ ❑ Are all. pumps operable?, N ❑ ❑ ❑ Are float controls. operable? - 0 ❑ ❑ ❑ Is SCADA telemetry available and operational? 0 ❑ ❑ ❑ Is audible and visual alarm available and operational? ❑ ❑ ❑ M Comment: All four pumps were operational. Primary Clarifier Yes No NA NE Is the clarifier free of black and odorous wastewater'? ❑ ❑ ❑ Is the site free of excessive buildup of solids in center well of circular clarifier? N ❑ .,❑ ❑ Are weirs -level? M ❑ ❑ ❑ - Is the site free of weir blockage? ❑ ❑ ❑ Is the site free of evidence of'short-circuiting? ❑ ❑ ❑ Is scum removal adequate? M ❑ ❑ ❑ Is the site free of excessive floating sludge? 0 ❑ ❑ ❑ Is the drive unit operational? N ~ ❑ ❑ ❑ Is the sludge.blanket level acceptable? 0 ❑ ❑ ❑ Is the sludge blanket level acceptable? (Approximately/ of the sidewall depth) 0 El, ❑ ❑ Comment: Both primaries were operational and in service. Nutrient Removal Yes No NA NE # Is total nitrogen removal required? - ,❑ ❑ ❑ # Is total phosphorous removal required? ❑ ❑ ❑ Type Biological # Is chemical feed•required to sustain process? ❑ ❑ ❑ Page# 6 rr Permit: NCO074268 Owner - Facility: Crowders Creek WV TP Inspection Date: 09/2012016 Inspection Type: Compliance Sampling Nutrient Removal Yes No NA NE Is nutrient removal process operating properly? ❑ El ❑ Comment: The subiect permit requires a 1.0 mg/L total phosphorus effluent limit and a seasonal (April 1 — October 31) 6.0 mg/L effluent total nitrogen limit Glycerin is added as a carbon source (anoxic basin). Aeration Basins Mode of operation Type of aeration system Is the basin free of dead spots? Are surface aerators and mixers operational? Are the diffusers operational? Is the foam the proper color for the treatment process? Does the foam cover less than 25% of the basin's surface? r Is the DO level acceptable? Is the DO level acceptable?(1.0 to 3.0 mg/1) Yes No NA NE Ext. Air Diffused - ■ ❑ ❑ ❑ 0,❑ M ❑ ,M ❑ ❑ ❑ ■ ❑ ❑ ❑ ❑. ❑� ❑ M -❑ . .❑ ❑ W ❑ 1:111 Comment: Foam was observed. No foam carry-over was observed in the secondaries: Secondary Clarifier Yes No NA NE Is the clarifier free of black and odorous wastewater? ❑ ❑ ❑ Is the site free of.excessive buildup of solids in center well of circular clarifier? ❑ ❑ `❑ Are weirs level? ❑ ❑ ❑ Is the site free of weir blockage? ❑ ❑ Is the site free of evidence of short-circuiting? - ❑ ❑ ❑ Is scum removal adequate? ❑ ❑ ❑ Is the site free of excessive floating sludge? ❑ ❑ ❑ Is the drive unit operational? M_. ❑ ❑ ❑ Is the return rate acceptable (low turbulence)? �; ❑ ❑ ❑ Is the overflow clear of excessive solids/pin floc? 0 ,❑ , 11, ❑ Is the sludge blanket level acceptable? (Approximately '/o of the sidewall depth) ❑ ❑ ❑ Comment:, ' Both secondaries were operational and in service. Alum is added on an as -needed basis to enhance settling. k Pumps -RAS -WAS Are pumps in place? Are pumps operational? Yes No NA NE S ❑ •❑ ❑ ■ ❑ El . ❑ Page# 7 Permit: NCO074268 Owner -Facility: Crowders Creek WWTP Inspection Date: 09/20/2016 Inspection Type: Compliance Sampling Pumps -RAS -WAS Yes No NA NE Are there adequate spare parts and supplies on site? ❑ ❑ ❑ Comment: Lagoons Yes No NA NE Type of lagoons? ❑ ❑ ❑ # Number of lagoons in operation at time of visit? 1 ❑ ❑ ❑ Are lagoons operated in? ❑ ❑ ❑ # Is a re -circulation line present? ❑ ❑ ❑ ❑ Is lagoon free of excessive floating materials? E ❑ ❑ ❑ # Are baffles between ponds or effluent baffles adjustable? ❑ ❑ 0 ❑ Are dike slopes' clear of woody vegetation? ■ ❑ ❑ ❑ Are weeds controlled around the edge of the lagoon? 0 ❑ ❑ ❑ Are dikes free of seepage? 0 ❑ ❑ ❑ Are dikes free of erosion? 0 ❑ ❑ ❑ Are dikes free of burrowing animals? ❑ ❑ ❑ # Has the sludge blanket in the lagoon (s) been measured periodically in multiple ❑ ❑ N ❑ locations? # If excessive algae is present, has barley straw been used to help control the growth? ❑ ❑ ❑ Is the lagoon surface free of weeds? ❑ ❑ ❑ Is the lagoon free' of short circuiting? ❑ ❑ ❑ Comment: : The facility is equipped with two polishing ponds (both lined and operational): however, only one pond was in service. The ponds are alternated approximately once every two years. Disinfection -Gas Yes No NA NE Are cylinders secured adequately? ❑ ❑ ❑ Are cylinders protected from direct sunlight? - N ❑ ❑ ❑ Is there adequate reserve supply of disinfectant? ❑ ❑ ❑ Is the level of chlorine residual acceptable? ❑ ❑ ❑ Is the contact chamber free of growth, or sludge buildup? N ❑ ❑ ❑ Is there chlorine residual prior to de -chlorination? ;N -❑ ❑ ❑ Does the Stationary Source have more than 2500 lbs of Chlorine (CAS No. 7782-50-5)? i ■ ❑ ❑ ❑ if yes,• then is there a Risk Management Plan on site? 0 ❑ ❑ ❑ If yes, then what is the EPA twelve digit ID Number? (1000-_-_) 1000-0006-7321 If yes, then when was the RMP last updated? 09/13/2016 Page# 8 Permit: NCOO74268 Owner -Facility: Crowders Creek WWTP Inspection Date: 09/2012016 Inspection Type: Compliance Sampling Disinfection -Gas Yes'No NA NE Comment: The chlorination and dechlorination systems are serviced annually. De -chlorination Type of system ? Is the feed ratio proportional to chlorine amount (1 to 1)? Is storage appropriate for cylinders? # Is de -chlorination substance stored away from chloririe containers? Comment: Are the tablets the proper size and type? Are tablet de -chlorinators operational? Number of tubes in use? Comment: Yes No NA NE Gas ❑ ❑ ❑ ❑ ❑ E ❑ ❑ ❑ M ❑ ❑ ❑ ■ ❑ .Flow Measurement - Effluent _Yes No NA NE # Is flow meter used for reporting? 0 ❑ ❑ ❑ Is flow meter calibrated annually? M' ❑ 11 ❑ Is the flow meter operational? 0 ❑ ❑ (If units are separated) Does the chart recorder match the flow meter? 0 ❑ ❑ ❑ Comment: The flow meter was last calibrated on 7/26/2016 by Fortech Automation Engineering.. Effluent Pipe Yes No NA NE Is right of way to the outfall properly maintained? M ❑ " ❑ ❑ Are the_receiving water free of foam other than trace amounts and other debris? 0 ❑ .❑ ❑ If effluent (diffuser pipes are required) .are they operating properly? ❑ ❑ 0 ❑ Comment: The effluent appeared clear with no floatable solids and trace foam (entrained air). Anaerobic Digester - Yes No NA NE Type of operation: Floating cover Is the capacity adequate? ❑ ❑ ❑ # Is gas, stored on site? � ❑ 0 ❑ Is the digester(s) free of tilting covers? ❑ ❑ ❑ Is the gas burner operational? 0 ❑ ❑ ❑ Is the digester heated? M ❑ ❑ ❑ Page# 9 Permit: NCO074268 Owner -Facility: Crowders Creek WWTP processes. Is automatically activated standby power available? Chemical Feed Inspection Date: 09/20/2016 Inspection Type: Compliance sampling Is containment adequate? ❑ ❑ ❑ Anaerobic Digester Yes No NA- NE Is the temperature maintained constantly? ❑ ❑ ❑ ❑ Is tankage available for properly waste sludge? Is the site free of excessive leaking? ❑ ❑ ❑ Comment: The facility is equipped with four digesters (1 -primary, 1 -secondary, 2 -holding tanks). N ❑ ❑ Bio -solids are land applied by a contracted company (EMA Resources) under Permit Is there an emergency agreement with a fuel vendor for extended run on back-up power? E ❑ W00001793. ❑ Is the generator fuel level monitored?' ❑ Solids Handling, Equipment -Yes No NANE Is the equipment operational? 0 ❑ ❑ ❑ ' Is the chemical feed equipment operational? ❑ ❑ M- ❑ Is storage adequate? ❑ ❑ ❑ Is the site free of high level of solids in filtrate from filter presses or vacuum filters? ❑ [I'M ❑ 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? ❑ ❑ ❑ Comment: Two DAF units: The DAF units are used to thicken the WAS Drior to digestion.- The DAF supernate is returned to the head of the biological/nutrient removal treatment processes. Is automatically activated standby power available? Chemical Feed Yes No NA NE Is containment adequate? ❑ ❑ ❑ Is storage -adequate? 0 ❑ ❑ ❑ Are backup pumps available? 0 ❑ ❑ ❑ Is the site free of excessive leaking? ❑ ❑ ❑ 1 N ❑ ❑ Comment: Standby-PoWer Yes No NA NE Is automatically activated standby power available? ❑ ❑ ❑ Is the generator tested by -interrupting primary power source? 0 • ❑ ❑ ❑ Is the generator tested under load? 0 ❑ ❑ - ❑ Was generator tested & operational during the inspection? ❑ ❑ ❑ Do the generators) have'adequate capacity to operate the entire wastewater site? N ❑ ❑ ❑ Is there an emergency agreement with a fuel vendor for extended run on back-up power? E ❑ ❑ ❑ Is the generator fuel level monitored?' ❑ ❑ ❑ Comment: Ali three standby „generators were operational. The generators are tested monthly under load and are serviced annually by a contracted company (CAT). Page# 10 6