NC0020184_Inspection_20181022

ROY COOPER
i�ov�w
MI HAEL S. RE AM
S-mr-ercry
LINDA CULPEPPER
lrrreri'm a'retrtor
NOPYH CARt')LINA
£reMilronmerttal QuaUr r
October 22, 2018
Ms. Stephanie Scheringer, Division Manager
Two Rivers Utilities
P.O. Box 1748
Gastonia, NC 28053
Subject: Compliance Evaluation Inspection
Long Creek WWTP
NPDES Permit No. NCO020184
Gaston County
Dear Ms. Scheringer:
Enclosed is a copy of the Compliance Evaluation Inspection for the inspection conducted
at the subject facility on October 22, 2018, by Ori Tuvia (a complete list of attendees can be found
on the attached report summary page). The assistance and cooperation of David Shellenbarger,
Doug Barker, Annette McMurray and yourself 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 [phone], or at
ori.tuvia(a�,ncdenr. gov.
Sincerely,
DocuSigned by:
A14CC681 AF27425...
W. Corey Basinger
Regional Supervisor
Mooresville Regional Office
Division of Water Resources
Cc: NPDES, MRO Files (Laserfiche)
Mooresville Regional Office
Location: 610 East Center Ave., Suite 301 Mooresville, NC 28115
Phone: [phone] Fax: [phone] 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 IN I 2 15 I 3 I NCO020184 111 12 I 18/10/17 I17 18 I S I 19 I G I 201 I
211111 1 1 I I I I II I I I I I I I I I I I I 1 I I I I I I I I I I II I I I I I f6
Inspection
Work Days Facility Self -Monitoring Evaluation Rating B1 QA ---------------------- Reserved -------------------
67
1.0 70 71 [„ I 72 n 73 L_LJ74 751
u u I I I I I I I80
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:OOAM 18/10/17
17/04/01
Long Creek WWTP
3000 Old Spencer Mountain Rd
Exit Time/Date
Permit Expiration Date
Dallas NC 28034
01:30PM 18/10/17
20/01/31
Name(s) of Onsite Representative(s)/Titles(s)/Phone and Fax Number(s)
Other Facility Data
Douglas Edward Barker/ORC/704-922-4086/
Name, Address of Responsible Official/Title/Phone and Fax Number
Contacted
Douglas E Barker,PO Box 1748 Gastonia NC 28053/Senior Plant
Operator/704-866-6991/7049220619 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
DocuSigned by:
Maria Schutte Division of Water Quality//704-663-1699) 10/22/2018
Ori A Tuvia MRO WQ//704-663-1699/
C -
Signature of Management Q A Reviewer Agency/Office/Phone and Fax Numbers Date
W. Corey Basinger Division of Water Quality//704-2;
EPA Form 3560-3 (Rev 9-94) Previous editions are obsolete.
DocuSigned by:
10/22/2018
AtaccsatAi=vazs... Page#

NPDES yr/mo/day Inspection Type
NC0020184 I11 121 18/10/17 117 18 JCJ
Section D: Summary of Finding/Comments (Attach additional sheets of narrative and checklists as necessary)
Cross training inspection attended by Winston Regional Office, Asheville Regional Office as Well as
Mooresville Regional Office.
List of attendants:
Scheringer, Stephanie
Shellenbarger, David
McMurray, Annette
Barker, Douglas
Schutte, Maria
Willmer, Mikal
Heim, Tim
Price, Bev
Wiggs, Linda
Boss, Daniel
Graznak, Jenny
DiMatteo, Paul
Kelli Park
Page#

Permit: NCO020184 Owner - Facility: Long Creek WWTP
Inspection Date: 10/17/2018 Inspection Type: Compliance Evaluation
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?
❑
0
❑
❑
Is access to the plant site restricted to the general public?
0
❑
❑
❑
Is the inspector granted access to all areas for inspection?
0
❑
❑
❑
Comment: The subject permit expires on 1/31/2020.
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?
0
❑
❑
❑
Is the chain -of -custody complete?
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 CM
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?
❑
❑
❑
Is a copy of the current NPDES permit available on site?
❑
❑
❑
Facility has copy of previous year's Annual Report on file for review?
❑
❑
❑
Comment: The records reviewed during the inspection were organized and well maintained. DMRs,
COCs, visitation logs, calibration logs and bench sheets were reviewed for the
period
December 2017 throuah Auaust 2018.
Influent Sampling
Yes No NA NE
Page# 3

Permit: NCO020184 Owner - Facility: Long Creek WWTP
Inspection Date: 10/17/2018 Inspection Type: Compliance Evaluation
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?
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: Permit requires both influent composite samples and grab sampling.
Aliquot sample taken during the inspection pulled 205 mi.
Effluent Sampling
Yes No NA NE
Is composite sampling flow proportional?
0
❑
❑
❑
Is sample collected below all treatment units?
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 the facility sampling performed as required by the permit (frequency, sampling type
0
❑
❑
❑
representative)?
Comment: Permit reauires both effluent composite samples (flow DrODortional) and arab samDlin
Aliquot sample taken during the inspection pulled 200 mi.
Upstream / Downstream Sampling Yes No NA NE
Is the facility sampling performed as required by the permit (frequency, sampling type, and 0 ❑ ❑ ❑
sampling location)?
Comment:
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?
0
❑
❑
❑
# 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?
❑
❑
0
❑
Incubator (BOD) set to 20.0 degrees Celsius +/- 1.0 degrees?
❑
❑
0
❑
Page# 4

Permit: NCO020184
Inspection Date: 10/17/2018
Laboratory
Owner - Facility: Long Creek WWTP
Inspection Type: Compliance Evaluation
Yes No NA NE
Comment: Influent and effluent analvses (includina field) are Derformed under the Citv's Crowders
Creek laboratory certification (#210). Meritech, Inc. (#129) (toxicity) and Shealy
Environmental (#329) (Hardnes,PPA, organics, Cyanide and chloroform) have also been
contracted to provide analytical support. The laboratory instrumentation used for field
analyses appeared to be properly calibrated and documented
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 ❑ ❑ ❑
Solids, pH, DO, Sludge Judge, and other that are applicable?
Comment: The facility appeared to be properly operated and well maintained. The operations staff
incorporate a comprehensive process control program with all documentation being properly
documented and maintained on -site. The facility is equipped with a SCADA system to assist
the operations staff with the monitoring of treatment processes and units.
Bar Screens
Yes No NA NE
Type of bar screen
a.Manual
❑
b.Mechanical
Are the bars adequately screening debris?
0
❑
❑
❑
Is the screen free of excessive debris?
0
❑
❑
❑
Is disposal of screening in compliance?
M
❑
❑
❑
Is the unit in good condition?
0
❑
❑
❑
Comment: Screenings and grit are disposed at the county landfill.
Grit Removal
Yes No NA NE
Type of grit removal
a.Manual
❑
b.Mechanical
Is the grit free of excessive organic matter?
0
❑
❑
❑
Is the grit free of excessive odor?
0
❑
❑
❑
# Is disposal of grit in compliance?
0
❑
❑
❑
Comment: Screenings and grit are disposed at the county landfill.
Pump Station - Influent Yes No NA NE
Is the pump wet well free of bypass lines or structures? 0 ❑ ❑ ❑
Page# 5

Permit: NCO020184
Inspection Date: 10/17/2018
Owner - Facility: Long Creek WWTP
Inspection Type: Compliance Evaluation
Pump Station - Influent
Yes No NA NE
Is the wet well free of excessive grease?
0
❑
❑
❑
Are all pumps present?
0
❑
❑
❑
Are all pumps operable?
0
❑
❑
❑
Are float controls operable?
0
❑
❑
❑
Is SCADA telemetry available and operational?
0
❑
❑
❑
Is audible and visual alarm available and operational?
0
❑
❑
❑
Comment: 4 of the 5 pumps were in operation during the inspection one pump #3 was out for
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'/4 of the sidewall depth)
0
❑
❑
❑
Comment: Two of three primaries were in service (all operational).
Nutrient Removal Yes No NA NE
# Is total nitrogen removal required? 0 ❑ ❑ ❑
# Is total phosphorous removal required? 0 ❑ ❑ ❑
Type Biological
# Is chemical feed required to sustain process? 0 ❑ ❑ ❑
Is nutrient removal process operating properly? 0 ❑ ❑ ❑
Comment: The facility, combined with Eagle Road WWTP, are required to comply with a summer (April
1 - October 31) effluent total nitrogen loading limit (214,171, lb/season) as well as winter
(November 1 — March 31) effluent total nitrogen loading limit (302,242 lb/season). The
combined facilities also have a year around effluent total phosphorus loading limit (60,882
lb/year). Nutrient removal is performed biologically and chemically (alum)
Aeration Basins
Yes No NA NE
Page# 6

Permit: NCO020184
Inspection Date: 10/17/2018
Owner - Facility: Long Creek WWTP
Inspection Type: Compliance Evaluation
Aeration Basins
Yes No NA NE
Mode of operation
Ext. Air
Type of aeration system
Diffused
Is the basin free of dead spots?
0
❑
❑
❑
Are surface aerators and mixers operational?
0
❑
❑
❑
Are the diffusers operational?
0
❑
❑
❑
Is the foam the proper color for the treatment process?
0
❑
❑
❑
Does the foam cover less than 25% of the basin's surface?
0
❑
❑
❑
Is the DO level acceptable?
0
❑
❑
❑
Is the DO level acceptable?(1.0 to 3.0 mg/1)
0
❑
❑
❑
Comment: 4 of the 4 aeration tracks were in operation during the inspection.
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:
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?
0
❑
❑
❑
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:
Filtration (High Rate Tertiary) Yes No NA NE
Page# 7

Permit: NCO020184
Inspection Date: 10/17/2018
Owner - Facility: Long Creek WWTP
Inspection Type: Compliance Evaluation
Filtration (High Rate Tertiary)
Yes No NA NE
Type of operation:
Down flow
Is the filter media present?
❑
❑
❑
Is the filter surface free of clogging?
❑
❑
❑
Is the filter free of growth?
❑
❑
❑
Is the air scour operational?
❑
❑
❑
Is the scouring acceptable?
❑
❑
❑
Is the clear well free of excessive solids and filter media?
❑
❑
❑
Comment: 4 of 8 tertiary filters were in service.
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?
E
❑
❑
❑
Does the Stationary Source have more than 2500 Ibs of Chlorine (CAS No. 7782-50-5)?
0
❑
❑
❑
If yes, then is there a Risk Management Plan on site?
❑
❑
❑
If yes, then what is the EPA twelve digit ID Number? (1000- - )
1000-0006-7367
If yes, then when was the RMP last updated?
Comment:
De -chlorination
Yes No NA NE
Type of system ?
Gas
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
❑
❑
Are the tablets the proper size and type?
❑
❑
0
❑
Comment: One ton cylinders are stored outside together under cover
Are tablet de -chlorinators operational? ❑ ❑ 0 ❑
Number of tubes in use?
Comment:
Page# 8

Permit: NCO020184
Inspection Date: 10/17/2018
Pumps-RAS-WAS
Are pumps in place?
Are pumps operational?
Are there adequate spare parts and supplies on site?
Comment:
Owner - Facility: Long Creek WWTP
Inspection Type: Compliance Evaluation
Flow Measurement - Effluent
# 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?
Yes No NA NE
■
❑
❑
❑
■
❑
❑
❑
■
❑
❑
❑
■ ❑ ❑ ❑
■ ❑ ❑ ❑
• ❑ ❑ ❑
• ❑ ❑ ❑
Comment: The influent and effluent flow meters are calibrated/verified twice per year and were last
calibrated/verifed on 5/9/2018.
Effluent Pipe
Yes No NA NE
Is right of way to the outfall properly maintained?
❑
❑
❑
Are the receiving water free of foam other than trace amounts and other debris?
❑
❑
❑
If effluent (diffuser pipes are required) are they operating properly?
❑
❑
❑
Comment: Effluent leaving the WWTP appeared clear with no floatable solids or foam. Effluent pipe
was not examined during the inspection.
Anaerobic Digester
Yes No NA NE
Type of operation:
Fixed cover
Is the capacity adequate?
❑
❑
❑
# Is gas stored on site?
❑ ❑
❑
Is the digester(s) free of tilting covers?
0 ❑
❑
❑
Is the gas burner operational?
❑ ❑
❑
Is the digester heated?
❑ ❑
❑
Is the temperature maintained constantly?
❑ ❑
❑
Is tankage available for properly waste sludge?
M ❑
❑
❑
Comment: Waste activated sludge (WAS) is thickened in a DAF unit prior to being pumped
to the
digesters. The facility is equipped with six anaerobic digesters (4-primary,
3 in operation
and 2-secondary). Bio-solids are land applied by a contracted company
(EMA) under the
authority of Permit No. WQ0001793.
Lagoons
Yes No NA NE
Page# 9

Permit: NC0020184 Owner - Facility: Long Creek WWTP
Inspection Date: 10/17/2018 Inspection Type: Compliance Evaluation
Lagoons Yes No NA NE
Type of lagoons?
# Number of lagoons in operation at time of visit? 2
Are lagoons operated in? Series
# Is a re -circulation line present?
❑
❑
0
❑
Is lagoon free of excessive floating materials?
0
❑
❑
❑
# Are baffles between ponds or effluent baffles adjustable?
❑
❑
0
❑
Are dike slopes clear of woody vegetation?
0
❑
❑
❑
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?
❑
❑
0
❑
# 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?
0
❑
❑
❑
Is the lagoon free of short circuiting?
❑
❑
0
❑
Comment: The facility is equipped with two lagoons used for bio-solids storage (prior
to land
application).
At the time of the inspection lagoons were being pumped and pressed
(sent to a landfill)
to
remove fiber glass.
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?
❑
❑
❑
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 facility is equipped with three standby generators that are placed under load at leat once
per month (peak shaving/storm events)
Page# 10