nc0023973_Compliance Evaluation Inspection_20180813

DocuSign Envelope ID: 5F32429F-49CA-4C95-82E8-7D15F140B922
ROY- COOPER NORTH CAROLINA
Gui.srtavr En vlrortmenrel Qu a ti ry
NIf [CFLAEL S. RE G --)—N
Jaerai¢rr
LLNDA CULPEPPER
,In tarrm Dirsciur
August 13, 2018
Steven Styers, ORC
Cape Fear Public Utility Authority
235 Government Center Drive
Wilmington, NC 28403
SUBJECT: Compliance Inspection
Wilmington Southside WWTP
NPDES WW Permit No. NCO023973
New Hanover County
Dear Permittee:
The North Carolina Division of Water Resources conducted an inspection of the Wilmington Southside
WWTP on 7/13/2018. This inspection was conducted to verify that the facility is operating in
compliance with the conditions and limitations specified in NPDES WW Permit No. NC0023973. The
findings and comments noted during this inspection are provided in the enclosed copy of the inspection
report entitled "Compliance Inspection Report".
There were no significant issues or findings noted during the inspection and therefore, a response to this
inspection report is not required. If you should have any questions, please do not hesitate to contact Tom
Tharrington with the Water Quality Regional Operations Section in the Wilmington Regional Office at
910-796-7215 or via email at tom,tharrington@ncdenrgov,
Sincerely,
DocuSigned by:
E
tevti((a S� 6"
E3ABA14AC7DC434...
Morella Sanchez -King, Regional Supervisor
Water Quality Regional Operations Section
Wilmington Regional Office
Division of Water Resources, NCDEQ
ATTACHMENTS
Cc: WQS Wilmington Regional Office — Laserfiche File
North Carolina Department of Environmental Quality I Division of Water Resources
127 Cardinal Drive Extension, Wilmington, North Carolina 28405
910-796-7215

DocuSign Envelope ID: BA8B7364-EC7B-4ED2-BCE9-8D87CD1926A1
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 IN I 2 15 I 3 I NCO023973 111 12 I 18/07/13 I17 18 I S J 19 LG] 201 I
211111 1 1 1 1 1 111 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 111 1 1 1 1 1 166
Inspection Work Days Facility Self -Monitoring Evaluation Rating 131 QA ----------------------Reserved-------------------
67 70 Id I 71 I I 72 I r, I 73I I I74 751 1 1 1 1 1 1 180
I—I I� I I 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 oermit Number)
10:10AM 18/07/13
18/03/01
Wilmington Southside WWTP
3436 River Rd
Exit Time/Date
Permit Expiration Date
Wilmington NC 28402
12:10PM 18/07/13
22/11/30
Name(s) of Onsite Representative(s)/Titles(s)/Phone and Fax Number(s)
Other Facility Data
Steven K Styers/ORC/910-332-6578/
Name, Address of Responsible Official/Title/Phone and Fax Number
Contacted
Steven Styers,235 Government Center Dr Wilmington NC
28403//910-332-6578/9103326730 No
Section C: Areas Evaluated During Inspection (Check only those areas evaluated)
Permit 0 Flow Measurement Operations & Maintenance Records/Reports
Self -Monitoring Program 0 Sludge Handling Disposal Facility Site Review Effluent/Receiving Waters
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
DocuSigned by: 8/13/2018
tbK16S , _LOQ WIRD WQ///
Ul.o�
Tom TharringtonE171F141E731361`3456...
Signature of Management Q A Reviewer Agency/Office/Phone and Fax Numbers Date
by: 8/14/2018
�ADoAc1uuSi'g'need
rVWY C.ii.(A
EPA Form 35603 9-Y§AiVfPF 'i6& editions are obsolete.
Page#

DocuSign Envelope ID: BA8B7364-EC7B-4ED2-BCE9-8D87CD1926A1
NPDES yr/mo/day Inspection Type (Cont.)
NCO023973 111 121 18/07/13 1 17 18 ICI
Section D: Summary of Finding/Comments (Attach additional sheets of narrative and checklists as necessary)
This site was visited on July 13, 2018 for a routine compliance inspection. The ORC and facility staff
were very knowledgeable about plant operations, troubleshooting issues, process control strategies
and discussed future expansion options. The bulk of the inspection comments are in the questions
section of the Water Compliance Report.
Facility staff provided numerous readings sheets, operations and maintenance logs, eDMR records,
Chain of Custody documents, bench sheets, ORC logs and analytical reports as requested. The bulk
of the wet chemistry testing is provided through the CFPUA centralized laboratory with additional
testing provided by Pace Laboratories.
This facility is a typical trickling filter process with a recycle pump station provided to return influent
back to the trickling filter for better treatment and to provide motive power for the rotating distribution
arm. Additionally, this site has a diffused -air aeration basin located after the filters. Here plant staff
maintain mixed liquor suspended solids in the 2,500 mg/I to 3,000 mg/I and use this basin to provide
additional treatment for BOD and ammonia removal. The effluent from this aeration basin is transferred
by screw lift pumps to the secondary clarifiers from which WAS is return to the aeration basin as
needed.
The anaerobic digesters consist of 4 tanks and are operated in series, the primary digester (#4) is a
1.0 MG vessel where the majority of the gas production occurs. Sludge is then transferred to digester
#2 which is a smaller 0.5 MG vessel and is used mostly as a point for gas storage. The sludge then
passes to digester #1 (0.5 MG) and then to digester #3 (0.5 MG). The sludge within these digesters is
manually transferred each shift. The latest NPDES renewal application indicates that this facility
currently produces 1,000 to 1,100 dry tons of residual each year.
The effluent flowmeter was last calibrated on January 22, 2018.
Page#

DocuSign Envelope ID: BA8B7364-EC7B-4ED2-BCE9-8D87CD1926A1
Permit: NCO023973
Inspection Date: 07/13/2018
Permit
Owner - Facility: Wilmington Southside WWTP
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?
Comment: The permit renewal application was provided to the central office on July 7, 2016.
Yes No NA NE
■ ❑ ❑ ❑
■ ❑ ❑ ❑
❑ ❑ ❑
❑ ❑ ❑
■ ❑ ❑ ❑
Operations & Maintenance Yes No NA NE
Is the plant generally clean with acceptable housekeeping? 0 ❑ ❑ ❑
Does the facility analyze process control parameters, for ex: MLSS, MCRT, Settleable ❑ ❑ ❑
Solids, pH, DO, Sludge Judge, and other that are applicable?
Comment: The site uses checksheets. loabooks and comDuter sDreadsheets to maintain records and
Mudge process control changes. Major process control items include primary clarifier
sludge/scum pumping rates, recirculation rates on trickling filters, settleability values and
effluent quality from the aeration basin. Trickling filters are flooded every 2 weeks with one
filter done every Friday. One primary clarifier (Clarifier #2) was out of service for
maintenance.
Bar Screens
Yes No NA NE
Type of bar screen
a.Manual
❑
b.Mechanical
0
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: The dual bar screens used at this facility are older units but function as originally designed.
Manual by-pass channels are available if needed for maintenance or unit breakdown.
Screenings are transported by conveyor to a rolling dumpster for storage until disposal.
Grit Removal Yes No NA NE
Type of grit removal
a.Manual ❑
b.Mechanical
Is the grit free of excessive organic matter? 0 ❑ ❑ ❑
Page# 3

DocuSign Envelope ID: BA8B7364-EC7B-4ED2-BCE9-8D87CD1926A1
Permit: NCO023973
Inspection Date: 07/13/2018
Owner - Facility: Wilmington Southside WWTP
Inspection Type: Compliance Evaluation
Grit Removal Yes No NA NE
Is the grit free of excessive odor? 0 ❑ ❑ ❑
# Is disposal of grit in compliance? 0 ❑ ❑ ❑
Comment: Grit is removed from a settlina tank that allows the sediment to settle due to velocitv chanae
The settled grit is swept to openings in the in the bottom of the sidewall by a scraper
mechanism where a step conveyor lifts the material to a conveyor belt for disposal. Each
treatment train has a separate grit removal unit. Flow through the settling tank keeps
organics and lighter material in suspension for removal in the primary clarifiers. The units
are older but appear well maintained and are functioning as designed.
Primary Clarifier
Yes No NA NE
Is the clarifier free of black and odorous wastewater?
0
❑
❑
❑
Is the site free of excessive buildup of solids in center well of circular clarifier?
0
❑
❑
❑
Are weirs level?
0
❑
❑
❑
Is the site free of weir blockage?
0
❑
❑
❑
Is the site free of evidence of short-circuiting?
0
❑
❑
❑
Is scum removal adequate?
0
❑
❑
❑
Is the site free of excessive floating sludge?
0
❑
❑
❑
Is the drive unit operational?
0
❑
❑
❑
Is the sludge blanket level acceptable?
0
❑
❑
❑
Is the sludge blanket level acceptable? (Approximately'/ of the sidewall depth)
0
❑
❑
❑
Comment: During the visit the #2 primary clarifier was our of service for repairs and
painting. If needed
the clarifier could be put into service. Sludge beds are determined with a core taker sample
taken during maintenance rounds.
Influent Sampling
Yes No NA NE
# Is composite sampling flow proportional?
0
❑
❑
❑
Is sample collected above side streams?
0
❑
❑
❑
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
0
❑
❑
❑
Celsius)?
Is sampling performed according to the permit?
0
❑
❑
❑
Comment: A flow proportional HACH Sigma 900 automatic sampler is used for influent sampling. The
cabinet temperature was 2.5°C during the inspection.
Trickling Filter Yes No NA NE
Is the filter free of ponding? 0 ❑ ❑ ❑
Page# 4

DocuSign Envelope ID: BA8B7364-EC7B-4ED2-BCE9-8D87CD1926A1
Permit: NCO023973 Owner - Facility:
Wilmington Southside WWTP
in the 2,500 mg/I to 3,000 mq/1 range and total
pounds of biomass are calculated as a
Inspection Date: 07/13/2018 Inspection Type:
Compliance Evaluation
control variable. A 30 -minute settlometer test for this basin is in the 250-300 SV range.
Trickling Filter
Yes No NA NE
Is the filter free of leaks at the center column of filter's distribution arms?
0
❑
❑
❑
Is the distribution of flow even from the distribution arms?
0
❑
❑
❑
Is the filter free of uneven or discolored growth?
0
❑
❑
❑
Is the filter free of sloughing of excessive growth?
0
❑
❑
❑
Are the filter's distribution arms orifices free of clogging?
0
❑
❑
❑
Is the filter free of excessive filter flies, worms or snails?
0
❑
❑
❑
Comment: Tricklina filter #1 uses a natural stone media and tricklina filter #2 uses stacked media
cubes. Both units were in service during the inspection and had uniform flow from the
distribution arms. Each filter is flooded every 2 weeks to combat nuisance flies.
Recirculation rates on the filters is based on flow needed to keep the distribution arms
moving, typically rates are increased during night time hours when flow into the facility
decreases.
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?
Is the DO level acceptable?
Is the DO level acceptable?(1.0 to 3.0 mg/1)
Yes No NA NE
Plug flow
Diffused
Comment: A smaller aeration basin is located downstream of the two tricklina filters to Drovide
E ❑ ❑ ❑
❑ ❑ ■ ❑
■ ❑ ❑ ❑
■ ❑ ❑ ❑
■ ❑ ❑ ❑
■ ❑ ❑ ❑
■ ❑ ❑ ❑
additional treatment and enhance nitrification rates. The mixed liquor levels are maintained
in the 2,500 mg/I to 3,000 mq/1 range and total
pounds of biomass are calculated as a
control variable. A 30 -minute settlometer test for this basin is in the 250-300 SV range.
Pumps -RAS -WAS
Yes No NA NE
Are pumps in place?
0
❑
❑
❑
Are pumps operational?
0
❑
❑
❑
Are there adequate spare parts and supplies on site?
0
❑
❑
❑
Comment: Pump stations are in place for trickling filter recycle, for RAS recycle to the aeration basin
and for filtrate return to the headworks.
Secondary Clarifier
Yes No NA NE
Page# 5

DocuSign Envelope ID: BA8B7364-EC7B-4ED2-BCE9-8D87CD1926A1
Permit: NCO023973 Owner - Facility:
Inspection Date: 07/13/2018 Inspection Type:
Wilmington Southside WWTP
Compliance Evaluation
Are cylinders secured adequately?
0
❑
Secondary Clarifier
Yes No NA NE
Is the clarifier free of black and odorous wastewater?
0
❑
❑
❑
Is the site free of excessive buildup of solids in center well of circular clarifier?
0
❑
❑
❑
Are weirs level?
0
❑
❑
❑
Is the site free of weir blockage?
❑
❑
❑
0
Is the site free of evidence of short-circuiting?
❑
❑
❑
0
Is scum removal adequate?
0
❑
❑
❑
Is the site free of excessive floating sludge?
0
❑
❑
❑
Is the drive unit operational?
N
❑
❑
❑
Is the return rate acceptable (low turbulence)?
0
❑
❑
❑
Is the overflow clear of excessive solids/pin floc?
0
❑
❑
❑
Is the sludge blanket level acceptable? (Approximately'/4 of the sidewall depth)
0
❑
❑
❑
Comment: The secondary clarifiers both have covers over the weirs to prevent algae build up. Sludge
blanket depths are checked during maintenance rounds by operations staff.
Disinfection -Gas
Yes No NA NE
Are cylinders secured adequately?
0
❑
❑
❑
Are cylinders protected from direct sunlight?
0
❑
❑
❑
Is there adequate reserve supply of disinfectant?
0
❑
❑
❑
Is the level of chlorine residual acceptable?
0
❑
❑
❑
Is the contact chamber free of growth, or sludge buildup?
0
❑
❑
❑
Is there chlorine residual prior to de -chlorination?
0
❑
❑
❑
Does the Stationary Source have more than 2500 lbs of Chlorine (CAS No. 7782-50-5)?
0
❑
❑
❑
If yes, then is there a Risk Management Plan on site?
0
❑
❑
❑
If yes, then what is the EPA twelve digit ID Number? (1000 -
If yes, then when was the RMP last updated?
Comment: The chlorine dosage from the chlorine gas cylinders is monitored by operators performing
colorimetric testing of effluent within the clorine contact chamber. With this result the
operator can adjust the chlorine dosage by changing
the setpoint of the controller which
adjusts the vacuum operated metering valve.
De -chlorination
Yes No NA NE
Type of system ?
Liquid
Is the feed ratio proportional to chlorine amount (1 to 1)?
❑ ❑
0
❑
Is storage appropriate for cylinders?
❑ ❑
0
❑
# Is de -chlorination substance stored away from chlorine containers?
0 ❑
❑
❑
Page# 6

DocuSign Envelope ID: BA8B7364-EC7B-4ED2-BCE9-8D87CD1926A1
Permit: NC0023973
Inspection Date: 07/13/2018
De -chlorination
Are the tablets the proper size and type?
Owner - Facility: Wilmington Southside WWTP
Inspection Type: Compliance Evaluation
Yes No NA NE
❑ ❑ ■ ❑
Comment: The operators use the chlorine residual readinas to adiust the sDeed of the chemical feed
pump that is dosing the dechlorination chemical. A chart listing the proper pump speed for
different combinations of total chlorine residual and effluent flow rate is provided for the
operators reference.
Are tablet de -chlorinators operational? ❑ ❑ 0 ❑
Number of tubes in use?
Comment: No comment
Anaerobic Digester
Yes No NA NE
Type of operation:
Floating
cover
❑
Is the capacity adequate?
0
❑
❑
❑
# Is gas stored on site?
0
❑
❑
❑
Is the digester(s) free of tilting covers?
Was generator tested & operational during the inspection?
❑
❑
❑
Is the gas burner operational?
Do the generator(s) have adequate capacity to operate the entire wastewater site?
❑
❑
❑
Is the digester heated?
Is there an emergency agreement with a fuel vendor for extended run on back-up power?
❑
❑
❑
Is the temperature maintained constantly?
Is the generator fuel level monitored?
❑
❑
❑
Is tankage available for properly waste sludge?
Comment: The site has two emergency generators, one for the main part of the WWTP and a
❑
❑
❑
Comment: The anaerobic diaesters are oDerated in series with the the scum and sludae from the
primary clarifiers and the thickened secondary waste sludge passing through anaerobic
digester #4 then to #2, then #1 and finally stored in #3. Most of the gas production occurs
within digester #4 and is stored in digester #2. Digested sludge is transferred from digester
#3 to a belt filter press before being stored in a covered sludge storage pad. Residuals are
disposed of as a Class B soil amendment on agricultural land.
Standby Power
Yes No NA NE
Is automatically activated standby power available?
0
❑
❑
❑
Is the generator tested by interrupting primary power source?
0
❑
❑
❑
Is the generator tested under load?
0
❑
❑
❑
Was generator tested & operational during the inspection?
❑
0
❑
❑
Do the generator(s) have adequate capacity to operate the entire wastewater site?
0
❑
❑
❑
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: The site has two emergency generators, one for the main part of the WWTP and a
secondary unit that is in place to provide power to the screw lift pumps
that are before the
secondary clarifiers.
Page# 7

DocuSign Envelope ID: BA8B7364-EC7B-4ED2-BCE9-8D87CD1926A1
Permit: NCO023973
Inspection Date: 07/13/2018
Owner - Facility: Wilmington Southside WWTP
Inspection Type: Compliance Evaluation
Effluent Sampling
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)?
Yes No NA NE
■
❑
❑
❑
■
❑
❑
❑
■
❑
❑
❑
■
❑
❑
❑
■
❑
❑
❑
■
❑
❑
❑
Comment: Effluent sampler was clean and appeared well maintained. Cabinet temperature was
maintained at 6.0°C or less.
Page# 8