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Home My WebLink AboutNC0074268_Compliance Evaluation Inspection_20180226Water Resources ENVIRONMENTAL QUALITY 26 February 2018 ROY COOPER Governor MICHAEL S REGAN Secretary LINDA CULPEPPER Interim Director RECE@VED/DENR/DWR Mr David Shellenbarger, Assistant Division Manager MAR 0 5 2018 Two Rivers Utilities Water Resources P.O. Box 1748 Permitting Section Gastonia, NC 28053 Subject: Compliance Inspection Crowders Creek WWTP NPDES Permit No. NCO074268 Gaston County Dear Mr. Shellenbarger: Enclosed is a copy of the Compliance Evaluation Inspection for the inspection conducted at the subject facility on February 21, 2018, by Maria Schutte and 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. 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. Sincerely, W Corey Basinger, Regional Supervisor Mooresville Regional Office Division of Water Resources, DEQ Cc: NPDES Unit Gaston County Health Department MRO Files Mooresville Regional Office Location 610 East Center Ave , Suite 301 Mooresville, NC 28115 Phone (704) 663-16991 Fax, (704) 663-6040 l 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 8-31-98 Section A National Data System Coding (I e, PCS) Transaction Code NPDES yr/mo/day Inspection Type Inspector Fac Type 1 N 1 2 15 I 3 I NCO074268 I11 121 18/02/21 I17 18 L C A 19 I S I 20I 211 I I I I I I I I I 11 I 1 I I I I I I I I I I I I I I I I I I I I I 11 I 1 1 I I 166 Inspection Work Days Facility Self -Monitoring Evaluation Rating B1 QA ----Reserved--------- 67 10 70 �d 71 l„ I 72 , 731 I 174 75I I I I I I I I80 LJ LJ I Section B Facility Data 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) 09 25AM 18/02/21 17/04/01 Crowders Creek WWTP Exit Time/Date Permit Expiration Date 5642 S York Rd 12 30PM 18/02/21 20/08/31 Gastonia NC 28052 Name(s) of Onsite Representative(s)fritles(s)/Phone and Fax Number(s) Other Facility Data Kevin Morgan Graves/ORC/704-214-9153/ Name, Address of Responsible OfficialrTitle/Phone and Fax Number Contacted Kevin M Graves,PO Box 1748 Gastonia NC 28053/Senior Plant No Operator/704-854-6655/7048669405 Section C Areas Evaluated During Inspection (Check only those areas evaluated) Permit E Flow Measurement Operations & Maintenance Records/Reports Self -Monitoring Program E 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 Mana Schutte Division of Water Quality/[704-663-1699i J i 2 §' 1(? On A Tuvia MRO WQ/[704-663-1699/ Signature of Management Q A Reviewer Agency/Office/Phone and Fax Numbers Date W Corey Basinger MRO WQ//704-235-2194/ EPA F r 560-3 (Rev 9-94 Previous editions�re obsolete 2,6 ,6�� Page# 1 NPDES yr/mo/day Inspection Type 1 31 NCO074268 111 121 18/02/21 117 18 i „ Section D Summary of Finding/Comments (Attach additional sheets of narrative and checklists as necessary) Page# 2 Permit NCO074268 Owner - Facility Crowders Creek WWfP inspection Date 02/21/2018 Inspection Type Compliance Evaluation Yes No NA NE Are records kept and maintained as required by the permit? 0 ❑ Permit Yes No NA NE (If the present permit expires In 6 months or less) Has the permittee submitted a new ❑ ❑ M ❑ application? ❑ ❑ ❑ 0 Is the facility as described In the permit? M ❑ ❑ ❑ # Are there any special conditions for the permit? 0 ❑ ❑ ❑ Is access to the plant site restricted to the general public? M ❑ ❑ ❑ Is the Inspector granted access to all areas for Inspection? 0 ❑ ❑ ❑ Comment The subject permit expires on 8/31/2020 Permit requires quarterly Hardness sampling for effluent and upstream but does not require the sampling to be done on the same day Record Keeping Yes No NA NE Are records kept and maintained as required by the permit? 0 ❑ ❑ ❑ Is all required Information readily available, complete and current? 0 ❑ ❑ ❑ 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? M ❑ ❑ ❑ 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 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 M ❑ ❑ ❑ on each shift? Is the ORC visitation log available and current? 0 ❑ ❑ ❑ Is the ORC certified at grade equal to or higher than the facility classification? 0 ❑ ❑ ❑ Is the backup operator certified at one grade less or greater than the facility classification? M ❑ ❑ ❑ Is a copy of the current NPDES permit available on site? M ❑ ❑ ❑ 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 DMRs, COCs ORC logs Calibration logs and Bench sheets were reviewed for the period Janaury 2017 through December 2017 Laboratory Yes No NA NE Page# 3 Permit NCO074268 Owner -Facility Crowders Creek WWTP Inspection Date 02/21/2018 Inspection Type Compliance Evaluation Yes No NA NE Is composite sampling flow proportional? M certification #210 Mentech Labs Inc (#165) and Shealy (#329) have been contracted to Laboratory Yes No NA NE Are field parameters performed by certified personnel or laboratory? 0 ❑ ❑ ❑ Are all other parameters(excluding field parameters) performed by a certified lab? N ❑ ❑ ❑ # Is the facility using a contract lab? N ❑ ❑ ❑ # Is proper temperature set for sample storage (kept at less than or equal to 6 0 degrees N ❑ ❑ ❑ Celsius)? Incubator (Fecal Coliform) set to 44 5 degrees Celsius+/- 0 2 degrees? 0 ❑ ❑ ❑ 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 Yes No NA NE Is composite sampling flow proportional? M certification #210 Mentech Labs Inc (#165) and Shealy (#329) have been contracted to ❑ ❑ provide analytical support N ❑ ❑ ❑ Influent Sampling Yes No NA NE # Is composite sampling flow proportional? 0 ❑ ❑ ❑ Is sample collected above side streams? M ❑ ❑ ❑ Is proper volume collected? N ❑ ❑ ❑ Is the tubing clean? N ❑ ❑ ❑ # Is proper temperature set for sample storage (kept at less than or equal to 6 0 degrees 0 ❑ ❑ ❑ Celsius)? Is sampling performed according to the permit? 0 ❑ ❑ ❑ Comment The subject 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 205 ml Influent sampler tubing had some sagging at the time of the Inspection Effluent Sampling Yes No NA NE Is composite sampling flow proportional? M ❑ ❑ ❑ Is sample collected below all treatment units? N ❑ ❑ ❑ Is proper volume collected? 0 ❑ ❑ ❑ Is the tubing clean? 0 ❑ ❑ ❑ # Is proper temperature set for sample storage (kept at less than or equal to 6 0 degrees N ❑ ❑ ❑ Celsius)? Is the facility sampling performed as required by the permit (frequency, sampling type ❑ ❑ ❑ representative)? Comment The subject permit requires composite and grab effluent sampling Monthly aliquot verifications are performed and documented At the time of the Inspection the effluent sampler pulled 208 ml Page# 4 rf Permit NCO074268 Owner - Facility Crowders Creek WNlrP Inspection Date 02/21/2018 Inspection Type Compliance Evaluation Upstream/ Downstream Sampling Yes No NA NE Is the facility sampling performed as required by the permit (frequency, sampling type, and ❑ ❑ ❑ sampling location)? Comment Operations & Maintenance Yes No NA NE Is the plant generally clean with acceptable housekeeping? N ❑ ❑ ❑ Does the facility analyze process control parameters, for ex MLSS, MCRT, Settleable 0 ❑ ❑ ❑ Solids, pH, DO, Sludge Judge, and other that are applicable? Comment The wastewater facllltti appeared to be properly operated and well maintained The ORC and staff Incorporate a comprehensive process control program (Including Chem -Scan 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 E ❑ ❑ ❑ a Manual ❑ ❑ ❑ ❑ b Mechanical N ❑ ❑ ❑ Are the bars adequately screening debris? 0 ❑ ❑ ❑ Is the screen free of excessive debris? 0 ❑ ❑ ❑ Is disposal of screening in compliance? 0 ❑ ❑ ❑ Is the unit in good condition? 0 ❑ ❑ ❑ Comment Flow Measurement - Influent Yes No NA NE # Is flow meter used for reporting? E ❑ ❑ ❑ Is flow meter calibrated annually? E ❑ ❑ ❑ Is the flow meter operational? ❑ ❑ ❑ (If units are separated) Does the chart recorder match the flow meter? ❑ ❑ ❑ Comment Flow meter was calibrated on 9/17/2017 by Expert Services Grit Removal Yes No NA NE Type of grit removal a Manual ❑ b Mechanical 0 Page# 5 Permit. NC0074268 Inspection Date 02/21/2018 Owner - Facility Crowders Creek wwrP Inspection Type Compliance Evaluation Is the pump wet well free of bypass lines or structures? M ❑ Grit Removal Yes No NA NE Is the grit free of excessive organic matter? M ❑ ❑ ❑ Is the grit free of excessive odor? 0 ❑ ❑ ❑ # Is disposal of grit In compliance? 0 ❑ ❑ ❑ Comment 0 ❑ ❑ ❑ Pump Station - Influent Yes No NA NE Is the pump wet well free of bypass lines or structures? M ❑ ❑ ❑ Is the wet well free of excessive grease? M ❑ ❑ ❑ Are all pumps present? 0 ❑ ❑ ❑ Are all pumps operable? M ❑ ❑ ❑ Are float controls operable? 0 ❑ ❑ ❑ Is SCADA telemetry available and operational? 0 ❑ ❑ ❑ Is audible and visual alarm available and operational? ❑ ❑ ❑ 0 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? ❑ ❑ ❑ Are weirs level? M ❑ ❑ ❑ Is the site free of weir blockage? 0 ❑ ❑ ❑ Is the site free of evidence of short-circuiting? N ❑ ❑ ❑ Is scum removal adequate? N ❑ ❑ ❑ Is the site free of excessive floating sludge? N ❑ ❑ ❑ Is the drive unit operational? 0 ❑ ❑ ❑ Is the sludge blanket level acceptable? M ❑ ❑ ❑ Is the sludge blanket level acceptable? (Approximately % of the sldewall depth) 0 ❑ ❑ ❑ Comment Both primaries were operational and In service Nutrient Removal Yes No NA NE # Is total nitrogen removal required? E ❑ ❑ ❑ # Is total phosphorous removal required? M ❑ ❑ ❑ Type Biological # Is chemical feed required to sustain process? 0 ❑ ❑ ❑ Page# 6 r Permit NCO074268 Inspection Date 02/21/2018 Nutrient Removal Is nutrient removal process operating properly? Owner - Facility Crowders Creek WV\!rP Inspection Type Compliance Evaluation Yes No NA NE N ❑ ❑ ❑ Comment The subject permit requires a total phosphorus and total nitrogen seasonal effluent loading Glycerin is added as a carbon source (anoxic basin) Aeration Basins Yes No NA NE Mode of operation Ext Air 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? Is the DO level acceptable? Is the DO level acceptable?(1 0 to 3 0 mg/1) Comment Foam was observed No foam carry-over was observed in the secondaries 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 sidewall depth) Diffused ■ ❑ N ❑ ❑ ❑ ❑ ❑ E ❑ • ❑ 110 ❑ • ❑ ❑ ❑ ■ ❑ ❑ ❑ ■ ❑ ❑ ❑ ■ ❑ ❑ ❑ Yes No NA NE ■ ❑ ❑ ❑ ■ ❑ 1:11:1 • ❑ 1:11:1 • ❑ ❑ ❑ • ❑ ❑ ❑ ■ ❑ ❑ ❑ N ❑ ❑ ❑ • ❑ ❑ ❑ • ❑ ❑ ❑ • ❑ ❑ ❑ ■ ❑ ❑ ❑ Comment Both secondaries were operational and in service Alum Is added on an as -needed basis to enhance settling Pumps -RAS -WAS Yes No NA NE Are pumps In place? 0 ❑ ❑ ❑ Are pumps operational? S ❑ ❑ ❑ Page# 7 Permit NCO074268 Owner -Facility Crowders Creek WWTP Inspection Date 02/21/2018 Inspection Type Compliance Evaluation Pumps -RAS -WAS Yes No NA NE Are there adequate spare parts and supplies on site? E ❑ ❑ ❑ Comment Lagoons Yes No NA NE Type of lagoons? ❑ Is the lagoon surface free of weeds? ❑ ❑ # Number of lagoons In operation at time of visit? 1 E ❑ ❑ ❑ Are lagoons operated In? however, only one pond was in service The ponds are alternated approximately once every # Is a re -circulation line present? ❑ ❑ N ❑ Is lagoon free of excessive floating materials? ❑ ❑ ❑ # Are baffles between ponds or effluent baffles adjustable? ❑ ❑ ❑ Are dike slopes clear of woody vegetation? ❑ ❑ ❑ Are weeds controlled around the edge of the lagoon? N ❑ ❑ ❑ Are dikes free of seepage? ❑ ❑ ❑ Are dikes free of erosion? ❑ ❑ ❑ Are dikes free of burrowing animals? E ❑ ❑ ❑ # Has the sludge blanket In the lagoon (s) been measured periodically In multiple ❑ ❑ 0 ❑ locations? # If excessive algae Is present, has barley straw been used to help control the growth? ❑ ❑ 0 ❑ Is the lagoon surface free of weeds? ❑ ❑ ❑ Is the lagoon free of short circuiting? E ❑ ❑ ❑ 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 Are cylinders secured adequately? Are cylinders protected from direct sunlight? Is there adequate reserve supply of disinfectant? Is the level of chlorine residual acceptable? Is the contact chamber free of growth, or sludge buildup? Is there chlorine residual prior to de -chlorination? Does the Stationary Source have more than 2500 lbs of Chlorine (CAS No 7782-50-5)? If yes, then Is there a Risk Management Plan on site? If yes, then what Is the EPA twelve digit ID Number? (1 000- - If yes, then when was the RMP last updated? Yes No NA NE N ❑ 1:11:1 ■ ❑ ❑ ❑ ■ ❑ ❑ ❑ ■ ❑ ❑ ❑ E ❑ ❑ ❑ N ❑ ❑ ❑ N ❑ ❑ ❑ N ❑ ❑ ❑ 100000067321 Page# 8 I Permit NCO074268 Owner -Facility Crowders Creek wwTP Inspection Date- 02/21/2018 Inspection Type Compliance Evaluation Disinfection -Gas Yes No NA NE Comment The chlorination and dechlorination systems are serviced annually De -chlorination Yes No NA NE Type of system ? Gas Is the feed ratio proportional to chlorine amount (1 to 1)? M ❑ ❑ ❑ Is storage appropriate for cylinders? 0 ❑ ❑ ❑ # Is de -chlorination substance stored away from chlorine containers? ❑ ❑ M ❑ Comment Are the tablets the proper size and type? ❑ ❑ M ❑ Are tablet de -chlorinators operational? ❑ ❑ M ❑ Number of tubes In use? Comment Flow Measurement - Effluent Yes No NA NE # Is flow meter used for reporting? M ❑ ❑ ❑ Is flow meter calibrated annually? M ❑ ❑ ❑ Is the flow meter operational? M ❑ ❑ ❑ (If units are separated) Does the chart recorder match the flow meter? (entrained air) ❑ ❑ ❑ Comment Flow meter was calibrated on 9/17/2017 by Expert Services Effluent Pipe Yes No NA NE Is right of way to the outfall properly maintained? 0 ❑ ❑ ❑ Are the receiving water free of foam other than trace amounts and other debris? M ❑ ❑ ❑ If effluent (diffuser pipes are required) are they operating properly? ❑ ❑ M ❑ 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? M ❑ ❑ ❑ # Is gas stored on site? 0 ❑ ❑ ❑ Is the digester(s) free of tilting covers? 0 ❑ ❑ ❑ Is the gas burner operational? ❑ ❑ ❑ Is the digester heated? ❑ ❑ ❑ Page# 9 Permit. NC0074268 Inspection Date 02/21/2018 Anaerobic Digester Is the temperature maintained constantly? Is tankage available for properly waste sludge? Owner - Facility. Crowders Creek VWVrP Inspection Type Compliance Evaluation Yes No NA NE N ❑ ❑ ❑ ■ ❑ ❑ ❑ Comment The facility Is equipped with four digesters (1 -primary 1 -secondary 2 -holding tanks) Bio -solids are land applied under Permit WQ0001793 Solids Handling Equipment Yes No NA NE Is the equipment operational? M ❑ ❑ ❑ Is the chemical feed equipment operational? ❑ ❑ M ❑ Is storage adequate? ❑ ❑ 0 ❑ Is the site free of high level of solids In filtrate from filter presses or vacuum filters? ❑ ❑ 0 ❑ Is the site free of sludge buildup on belts and/or rollers of filter press? ❑ ❑ 0 ❑ Is the site free of excessive moisture In belt filter press sludge cake? ❑ ❑ 0 ❑ The facility has an approved sludge management plan? 0 ❑ ❑ ❑ Comment Two DAF units The DAF units are used to thicken the WAS prior to digestion The DAF supernate Is returned to the head of the blclogical/nutrient removal treatment processes Is automatically activated standby power available? 0 ❑ ❑ ❑ Chemical Feed Yes No NA NE Is containment adequate? 0 ❑ ❑ ❑ Is storage adequate? 0 ❑ ❑ ❑ Are backup pumps available? 0 ❑ ❑ ❑ Is the site free of excessive leaking? 0 ❑ ❑ ❑ Comment Standby Power Yes No NA NE Is automatically activated standby power available? 0 ❑ ❑ ❑ Is the generator tested by Interrupting primary power source? N ❑ ❑ ❑ Is the generator tested under load? M ❑ ❑ ❑ Was generator tested & operational during the Inspection? ❑ ❑ ❑ M Do the generator(s) have adequate capacity to operate the entire wastewater site? M ❑ ❑ ❑ Is there an emergency agreement with a fuel vendor for extended run on back-up power? 0 ❑ ❑ ❑ Is the generator fuel level monitored? 0 ❑ ❑ ❑ Comment All three standby generators were operational The generators are tested monthly under load and are serviced annually by a contracted company (CAT) Page# 10