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Home My WebLink AboutNC0063096_Compliance Evaluation Inspection_20171121 (2)November 21, 2017 Seann Byrd, Water Quality Director Holly Springs Utley Creek Water Reclamation Facility P O Box 8 Holly Springs, NC 27540 Subject Compliance Evaluation Inspection Utley Creek Water Reclamation Facility NPDES Permit NCO063096 Wake County Dear Mr Byrd ROY COOPER (mu>rrrnr MICHAEL S REGAN sec, elco" Linda Culpepper hiterim Dir uoi Mitch Hayes of the Raleigh Regional Office conducted the subject inspection on November 16, 2017 The assistance of Terry Foster, Chief Operator, and Amy Moore, Laboratory Supervisor, with this inspection was greatly appreciated Please find attached to this letter, the Basinwide Information Management System (BIMS) checklist summarizing the inspection Below is a list of findings developed from the inspection and review of the permit The subject permit became effective November 1, 2017 and will expire July 31, 2021 Significant changes to the permit include a) Effluent Pollutant Scan must be performed during 2017, 2019, and 2020 b) Calculation of total nitrogen and total phosphorus loads has been removed from the permit c) Second species Toxicity Testing Requirements for municipal permit renewals per Federal Regulations [40 CFR 122 21 0)(5)] have been added d) Mercury limitation is not required e) A Mercury Minimization Plan must be developed by April 30, 2018 and shall be available for inspection on-site f) Quarterly monitoring for chlorides was added to the permit g) Monthly monitoring and limitations for total lead were added to the permit h) Monitoring for copper and zinc has been removed i) Future sampling for arsenic, cadmium and silver as part of the facility's Pretreatment Program and Effluent Pollutant Scans should analyze these parameters down to the lower reporting level of the procedure or DWR's Laboratory PQL j) Effluent hardness and Instream hardness sampling, upstream of the discharge has been added to the permit 2 The 6 0 MGD Biological Nutrient Reduction (BNR) water reclamation facility consists of the following units ultra — sonic influent flow meter, mechanical bar screens, a cyclone screenings separator, vortex -type grit collector, influent pump station with six -(6) ABS pumps, three (3) - oxidation ditches using Bardenpho 5-statge process for BNR removal, three (3) secondary clarifiers, coagulation basin with chemical feed for total phosphorus removal, four (4) banks of Hydrotech cloth discfilters, two (2) UV banks for disinfection, r•--, Division of Watei Re6ources, Raleigh Regional Office, Water Quality Operations Section htti) "portal nedeni oig/web/wq/aps 1628 Marl Service Center, Raleigh, NC 27699-1625 Phone (919) 791-4200 Location 3800 Baiiett Drive, Raleigh, NC 27609 Fax (919) 785-7159 reclaimed water pump station with conjunctive reuse system, ultra — sonic effluent flow meter, a covered step cascade aeration pad, RAS pump station, interchange tanks with mixers and diffused aeration, decant clarifier, aerobic digester, aerated sludge tank, a volute sludge press system, and two (2) on-site generators, a reclaimed water pump station for conjunctive reuse system All operations are controlled by SCADA At the time of inspection, the automatic bar screen and vortex grit removal system were functioning normally, two out of three oxidation ditches were in operation due to low inflow, two out of three secondary clarifiers were in operation due to low inflow, the Hydrotech cloth discfilters were operating normally, all UV banks were in operation, the sludge press was being operated, one of two on-site generators was in operation, effluent at the cascade aerator appeared clear with little foam and no solids 4 The laboratory was checked in a cursory manner The laboratory certification 37408 is current and will expire December 31, 2017, Merritech Labs analyses toxicity, total nitrogen, nitrate, ortho - nitrate, chlorophyll a, and all instream - monitoring All pH buffers were within expiration date At, the time of inspection, the sample refrigerator was 3 0 degrees C, fecal coliform bath was 44-5 degrees C, and the BOD incubation chamber was 20 0 degrees C 5 Discharge Monitoring Reports (DMR s) for the period August 2015 through September 2017 were reviewed for compliance with permit limits and monitoring requirements Monthly and weekly violations were noted in August 2017 for Total Nitrogen (TN) and Total Phosphorus (TP) BOD limit violations were noted for both August and September 2017 For September 2017, BOD limit violations were noted as well as TN and TP frequency violations These limit and monitoring violations will be addressed in separate correspondence 6 Commercial lab results, chain of custody records, and bench sheets were compared with data submitted on the DMR for the month of September 2,017 No discrepancies were noted I would like to thank Terry Foster and Amy Moore for their time and assistance with this inspection If you have any questions about this letter or 'the inspection, please contact Mitch Hayes at 919 791 4261 or b ✓ email at r cl=r, cc Permit files, Central fles Sincerely, Danny Smith, Regional Supervisor Water Quality Regional Operations Section Raleigh Regional Office Division of Water Resources, DEQ 717 h�^LtL,,4:ZusL United States Environmental Protection Agency Form Approved EPA Washington, D C 20460 OMB No 2040-0057 Water Compliance Inspection Report Approval expires 8-31-98 Section A National Data System Coding (i e , PCS) Transaction Code NPDES yr/molday Inspection Type Inspector Fac Type 1 IN 1 2 15 1 3 I NCO063096 111 121 17/11/16 I17 18 1, 1 19 L G I 201 211 1 1 1 1 1 1 I I 1 1 1 1 I 11 1 1 1 1 I I I 1 1 I 1 I 1 1 1 1 1 1 1 1 1�I 1 1 1 1 l66 Inspection Work Days Facility Self-Monitoring Evaluation Rating B1 QA ---------------------Reserved------------------- 67 70 71 I I 72 1 N 1 L—I I—I 73 I I 174 751 1 1 1 1 1 _jj80 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 permit Number) 10 30AM 17/11/16 17/11/01 Holly Springs WWTP Exit Time/Date Permit Expiration Date NCSR 1115 12 30PM 17/11/16 21/07/31 Holly Springs NC 27540 Name(s) of Onsite Representative(s)/Titles(s)/Phone and Fax Number(s) Other Facility Data 111 Kai Jackson Vannoy/ORC/910-584-1887/ Seann Byrd/Director Public Utilities/919-577-1090 /9195772280 Terry Ray Foster//919-577-1090 / Terry Ray Foster/ORC/919-577-1090/ Name, Address of Responsible Official/Title/Phone and Fax Number Contacted Charles Simmons,128 S Main St Holly Springs NC 27540ITown Yes Manager/919-557-3938/9195529881 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 Mitchell S,�Hayes /�P RRO WQ//919-791-4200/ I / /// /I 7 s"l j f Sfgnat re of Managers Reviewve'r Ag`enc'y/OfficelPhpphe and Fax'Numbe�rs Date — EPA Form 3560-3 (Rev 9-94) Previous editions are obsolete Page# NPDES yr/mo/day Inspection Type (Cont) 1 31 NCO063096 111 121 17/11/16 1 17 18 I c i Section D Summary of Finding/Comments (Attach additional sheets of narrative and checklists as necessary) 1 The subject permit became effective November 1, 2017 and will expire July 31, 2021 Significant changes to the permit Include a) Effluent Pollutant Scan must be performed during 2017, 2019, and 2020 b) Calculation of total nitrogen and total phosphorus loads has been removed from the permit c) Second species Toxicity Testing Requirements for municipal permit renewals per Federal -- - - - Regu:ations [40 CFR 122 210)(5)] have been added d) Mercury limitation Is not required e) A Mercury Minimization Plan must be developed ty April 30, 2018 and shall be available for inspection on-site f) Quarterly monitoring for chlorides was added to the permit g) Monthly monitoring and limitations for total lead were added to the permit h) Monitoring for copper and zinc has been removed I) Future sampling for arsenic, cadmium and silver as part of the facility's Pretreatment Program and Effluent Pollutant Scans should analyze these parameters down to the lower reporting level of the procedure or DWR's Laboratory PQL )) Effluent hardness and instream hardness sampling, upsrream of the discharge has been added to the permit The 6 0 MGD Biological Nutrient Reduction (BNR) water reclamation facility consists of the following units ultra — sonic influent flow meter, mechanical bar screens, a cyclone screenings separator, vortex -type grit collector, influent pump station with six (6) ABS pumps, three (3) - oxidation ditches using Bardenpho 5-statge process for BNR removal, three (3) secondary clarifiers, coagulation basin with chemical feed for total Dhosphorus removal, four (4) banks of Hydrotech cloth discfilters, two (2) UV banks for disinfection, reclaimed water pump station with conjunctive reuse system, ultra — sonic effluent flow meter, a covered step cascade aeration pad, RAS pump station, Interchange tanks with mixers and diffused aeration, decant clarifier, aerobic digester, aerated sludge tank, a volute sludge press system, and two (2) on-site generators, a reclaimed water pump station for conjunctive reuse system All operations are controlled by SCADA At the time of inspection, the automatic bar screen and vortex grit removal system were functioning normally, two out of three oxidaticn ditches were in operation due to low Inflow, two out of three secondary clarifiers were in operation due to low inflow, the Hydrotech cloth discfilters were operating normally, all UV banks were in operation, the sludge press was being operated, one of two on-site generators was in operation, effluent at the cascade aerator appeared clear with little foam and no solids The laboratory was checked In a cursory manner The laboratory certification 37408 Is current and will expire December 31, 2017 Merritech Labs analyses toxicity, total nitrogen, nitrate, ortho - nitrate, chlorophyll a, and all instream - monitoring All pH buffers were within expiration date At the time of inspection, the sample refrigerator was 3 0 degrees C, fecal coliform bath was 44 5 degrees C, and the BOD incubation chamber was 20 0 degrees C Discharge Monitoring Reports (DMR's) for the period August 2015 through September 2017 were reviewed for compliance with permit limits and monitoring requirements Monthly and weekly permit limit violations for BOD were noted for August 2017 and 08 26 2017 along with frequency violations for August Total Nitrogen (TN), and Total Phosphorus (TP) weekly and August violations This Notice of Violation is in review Weekly permit limit violation for BOD 09 02 2017 along with TN and TP frequency violations for September 2017 were noted The September violations will be addressed in future correspondence Page# Permit NCO063096 Inspection Date 11/16/2017 Owner - Facility Holly Springs IMNTP Inspection Type Compliance Evaluation Commercial lab results, chain of custody records, and bench sheets were compared with data submitted on the DMR for the month of September 2017 No discrepancies were noted Page# Permit NCO063096 Inspection Date 11/16/2017 Operations & Maintenance Is the plant generally clean with acceptable housekeeping? Owner - Facility Holly Springs WVVTP Inspection Type Compliance Evaluation Does the facility analyze process control parameters, for ex MLSS, MCRT, Settleable Solids, pH, DO, Sludge Judge, and other that are appl,cable? Comment Permit (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? i Yes No NA NE • ❑ ❑ ❑ • ❑ ❑ ❑ Yes No NA NE ❑ ❑ ® ❑ ■ ❑ ❑ ❑ ■ ❑ ❑ ❑ ■ ❑ ❑ ❑ ® ❑ ❑ ❑ Comment A Mercury Minimization Plan must be developed by April 30 2018 and shall be available for inspection, on-site Record Keeping Yes No NA NE Are records kept and maintained as required by the permit? ■ ❑ ❑ ❑ Is all required Information readily available, complete and current? ® ❑ ❑ ❑ Are all records maintained for 3 years (lab reg required 5 years)? ® ❑ ❑ ❑ Are analytical results consistent with data reported on DMRs? ® ❑ ❑ ❑ Is the chain -of -custody complete? ® ❑ ❑ ❑ Dares, 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? M ❑ ❑ ❑ Has the facility submitted its annual compliance report to users and DWQ? IE ❑ ❑ ❑ (If the facility Is = or > 5 MGD permitted flow) Do they operate 24/7 with a certified operator 0 ❑ ❑ ❑ on each shift? Is the ORC visitation log available and current? 11 ❑ ❑ ❑ Is the ORC certified at grade equal to or higher'than the facility classification? 9 ❑ ❑ ❑ Is the backup operator certified at one grade less or greater than the facility classification? 9 ❑ ❑ ❑ Is a copy of the current NPDES permit available on site? IN ❑ ❑ ❑ Page# 4 Permit NCO063096 Inspection Date 11/16/2017 Record Keeping Facility has copy of previous year's Annual Report on file for review? Owner - Facility Holly Springs VWVTP Inspection Type Compliance Evaluation Yes No NA NE ■ ❑ 1:11:1 Comment Commercial lab results, chain of custody records, and bench sheets were compared with data submitted on the DMR for the month of September 2017 No discrepancies were noted The WRF Is now operating at 6 0 MGD Effluent Pipe Yes No NA NE Is right of way to the outfall properly maintained? i ❑ ❑ ❑ Are the receiving water free of foam other than trace amounts and other debris? ■ ❑ ❑ ❑ If effluent (diffuser pipes are required) are they operating properly? ❑ ❑ N ❑ Comment Effluent appeared clear with little foam Flow Measurement - Influent Yes No NA NE # Is flow meter used for reporting? ❑ 0 ❑ ❑ Is flow meter calibrated annually? 0 ❑ ❑ ❑ Is the flow meter operational? N ❑ ❑ ❑ (If units are separated) Does the chart recorder match the flow meter? ❑ ❑ ❑ ■ Comment Effluent flow Is used for reporting Flow Measurement - Effluent Yes No NA NE # 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? ❑ ❑ n in Comment Flow meters are calibrated annual) Aerobic Digester Yes No NA NE Is the capacity adequate? ® ❑ ❑ ❑ Is the mixing adequate? ® ❑ ❑ ❑ Is the site free of excessive foaming In the tank? ® ❑ ❑ ❑ # Is the odor acceptable? ® ❑ ❑ ❑ # Is tankage available for properly waste sludge? ® ❑ ❑ ❑ Comment Page# 5 Permit NC0063096 Owner - Facility Holly Springs VVVVTP Inspection Date 11/16/2017 Inspection Type Compliance Evaluation Yes No NA NE Is containment adequate? O Solids Handling Equipment Yes No NA NE Is the equipment operational? ■ ❑ ❑ ❑ Is the chemical feed equipment operational? N ❑ ❑ ❑ Is storage adequate? 0 ❑ ❑ ❑ 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? ❑ ❑ N ❑ Is the site free or excessive moisture In belt filter press sludge cake? ❑ ❑ ■ ❑ The facility has an approved sludge management plan? ® ❑ ❑ ❑ Comment The WRF utilizes a volute sludge press system Chemical Feed Yes No NA NE Is containment adequate? O ❑ ❑ ❑ Is storage adequate? ® ❑ ❑ ❑ Are backup pumps available? ® ❑ ❑ ❑ Is the site free of excessive leaking? ® ❑ ❑ ❑ Comment liquid sodium aluminate and MlcorC are used In the process Pump Station - Influent Yes No NA NE Is the pump wet well free of bypass Imes or structures? ® ❑ ❑ ❑ Is the wet well free of excessive grease? ® ❑ ❑ ❑ Are all pumps P -sent? ® ❑ ❑ ❑ Are all pumps operable? ® ❑ ❑ ❑ Are float controls operable? ❑ ❑ ❑ ❑ Is SCADA telemetry available and operational? K ❑ ❑ ❑ Is audible and visual alarm available and operational? N ❑ ❑ ❑ Comment Bar Screens Yes No NA NE Type of bar screen a Manual ❑ b Mechanical Are the bars adequately screening debris? 11 ❑ ❑ ❑ Is the screen free of excessive debris? R ❑ ❑ ❑ Is disposal of screening In compliance? N ❑ ❑ ❑ Page# 6 Permit NCO063096 Owner - Facility Holly Springs WWTP Inspection Date 11/16/2017 Inspection Type Compliance Evaluation Bar Screens Yes No NA NE Is the unit In good condition? E ❑ ❑ ❑ Comment Grit Removal Yes No NA NE Type of grit removal ■ ❑ ❑ a Manual ❑ ❑ ❑ b Mechanical E ❑ ® Is the grit free of excessive organic matter? 0 ❑ ❑ ❑ Is the grit free of excessive odor? 0 ❑ ❑ ❑ # Is disposal of grit In compliance? E ❑ ❑ ❑ Comment Secondary Clarifier Is the clarifier free of black and odorous wastewater? Is the site free of excessive buildup of solids In center well of circular clarifier? Are weirs level? Is the site free of weir blockage? Is the site free of evidence of short-circuiting? Is scum removal adequate? Is the site free of excessive floating sludge? Is the drive unit operational? Is the return rate acceptable (low turbulence)? Is the overflow clear of excessive solids/pin floc? Is the sludge blanket level acceptable? (Approximately % of the sldewall depth) Comment Weirs are covered to prevent algae growth Oxidation Ditches Are the aerators operational? Are the aerators free of excessive solids build up? # Is the foam the proper color for the treatment process? Does the foam cover less than 25% of the basin's surface? Is the DO level acceptable? Are settleometer results acceptable (> 30 minutes)? Yes No NA NE ■ ❑ ❑ ❑ ■ ❑ ❑ ❑ ❑ ❑ ❑ ■ ■❑❑❑ ❑ ® ❑ ❑ ❑ ❑ ■ ■❑❑❑ ❑ ® ❑ r❑❑❑ ❑ ■ ❑ ❑ ❑ ® ❑ ❑ ❑ 2 E El ❑ ❑ ❑ Yes No NA NE ® ❑ ❑ ❑ ® ❑ ❑ ❑ ® ❑ ❑ ❑ ® ❑ ❑ ❑ ® ❑ ❑ ❑ Page# 7 Permit NC0063096 •r' Inspection Date 11/16/2017 Owner - Facility Holly Springs VwvTp Inspection Type Compliance Evaluation Oxidation Ditches Is the DO level acce table? Yes No NA NE p (1 0 to 3 0 mg/I) Are settelometer results acce table? 0 El El p (400 to 800 ml/I In 30 minutes) Comment Influent appeared medium to dark brown in color ❑ ❑ ❑ ■ - Type of operation Yes No NA NE Is the filter media present? Cross flow Is the filter surface free of clogging? ❑ ❑ ! ❑ Is the filter free of growth? ❑ ❑ M ❑ Is the air scour operational? ❑ ❑ 0 ❑ Is the scouring acceptable? ❑ ❑ M ❑ Is the clear well free of excessive solids and filter media? ❑ ❑ ! ❑ ❑ ❑ ■ ❑ Comment Facilltv utilizes four (4) banks of Hydrotech cloth discfilters that are in a closed environment Disinfection - UV Are extra UV bulbs available on site? Are UV bulbs clean? Is UV intensity adequate? Is transmittance at or above designed level? Is there a backup system on site? is effluent clear and free of solids? Comment Effluent appeared clear at the cascade aerator Standby Power Is automatically activated standby power available? Is the generator tested by interrupting primary power source? Is the generator tested under load? Jas generator tested & operational during the inspection? o the generator(s) have adequate capacity to operate the entire wastewater site? there an emergency agreement with a fuel vendor for extended run on back-up power? the generator fuel level monitored? :omment One out of two on-site generators was in operation during the inspection Yes No NA NE ■ ❑ ❑ ❑ M ❑ ❑ ❑ • ❑ ❑ ❑ • ❑ ❑ ❑ ■ ❑ ❑ ❑ ® ❑ ❑ ❑ Yes No NA NE Page# 8 Permit NCO063096 Inspection Date 11/16/2017 Pumps -RAS -WAS Are pumps in place? Are pumps operational? Are there adequate spare parts and supplies on site? Comment RAS pump station was operating normally Owner - Facility Holly Springs V VVTP Inspection Type Compliance Evaluation Laboratory Are field parameters performed by certified personnel or laboratory? Are all other parameters(excluding field parameters) performed by a certified lab? # 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)? Incubator (Fecal Coliform) set to 44 5 degrees Celsius+/- 0 2 degrees? Incubator (BOD) set to 20 0 degrees Celsius +/- 1 0 degrees? Yes No NA NE • ❑ ❑ ❑ • ❑ ❑ ❑ • ❑ ❑ ❑ Yes No NA NE • ❑ ❑ ❑ • ❑ ❑ ❑ ® ❑ ❑ ❑ ® ❑ ❑ ❑ ® ❑ ❑ ❑ ■ ❑ ❑ ❑ Comment Merritech Labs analyses toxicity total nitrogen, nitrate, ortho - nitrate, chlorophyll a, and all Instream - monitoring Effluent Sampling Yes No NA NE Is composite sampling flow proportional? N ❑ ❑ ❑ 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 0 ❑ ❑ ❑ representative)? Comment Upstream / Downstream Sampling Yes No NA NE Is the facility sampling performed as required by the permit (frequency, sampling type, and E ❑ ❑ ❑ sampling location)? Comment Effective Nov 1 2017 Instream monitorinq is In effect Nutrient Removal Yes No NA NE # Is total nitrogen removal required? N ❑ ❑ ❑ # Is total phosphorous removal required? M ❑ ❑ ❑ Page# 9 Permit NC0063096 Inspection Date 11/16/2017 Nutrient Removal Type # Is chemical feed required to sustain process? Is nutrient removal process operating properly? Comment liquid sodium aluminate Is used for TP removal Owner - Facility Holly Springs WWTP Inspection Type Compliance Evaluation Yes No NA NE Biological ❑ ■ ❑ ❑ ■ ❑ ❑ ❑ Page# 10