WQ0018755_Staff Report_20190305

Dow& n EnveloC1D:91C9B03F-C244-4BD5-AAEC-1B326EA5FOAF
State of North Carolina
Division of Water Resources
Water Quality Regional Operations Section
Environmental Staff Report
Quality
To: ❑ NPDES Unit ® Non -Discharge Unit
Attn: (Tessa Monday)
From: (Tom Tharrington)
Wilmington Regional Office
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1. Was a site visit conducted? ® Yes or ❑ No
a. Date of site visit: 02-12-2019
b. Site visit conducted by: Tom Tharrington
c. Inspection report attached? ® Yes or ❑ No
Application No.: Aqua North Carolina, Inc. WQ0018755
Facility Name: Castle Bay WWTP
d. Person contacted: Charles Bryan and their contact information: [phone]
e. Driving directions: Follow US-17N from Wilmington to Hampstead, turn left on Hoover Road (SR 1569) and
follow for approximately 2.0 miles and turn right onto Castle Bay Drive. Follow Castle Bay Drive to first gravel
road on the right and follow to WWTP.
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II. PROPOSED FACILITIES: NEW APPLICATIONS
3. Are depth tewa4er-
table, the
Ej Yes E No D N�A
site eenditions (soils,
ete) eensistent with
s4miffed r-epol4s?
if no, please •
ifno, please explaiw:
5. is the
ao,.,, �o� n Yes n N
n N k
proposed r-esiduals management
if
plan
no, please •
if
no, please explain
FORM: WQROSSR 04-14 Page 1 of 4

DocuSign Envelope ID: 91C9B03F-C244-4BD5-AAEC-1B326EA5FOAF
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11. P_rot a t,v e t P,-oR,-.,m (POTWs only):
III. EXISTING FACILITIES: MODIFICATION AND RENEWAL APPLICATIONS
1. Are there appropriately certified Operators in Charge (ORCs) for the facility? ® Yes ❑ No ❑ N/A
ORC: Charles G. Bryan
Backup ORC: Kirklyn B. Fields
Certificate #: WW-2,1002563
Certificate #: WW-3, 996782
2. Are the design, maintenance and operation of the treatment facilities adequate for the type of waste and disposal
system? ® Yes or ❑ No
If no, please explain:
Description of existing facilities: The Castle Bay WWTF is a 100,000 GPD dual train extended aeration
activated sludge process with spray irrigation disposal.
Influent wastewater enters a single 25,000 gallon aerated flow equalization tank through a single manually
cleaned bar screen and dual adjustable weirs for flow control to each train. A single 85 cfm blower provides
aeration for this equalization tank, and dual 50 gpm flow equalization pumps are used to transfer influent into the
aeration tanks and are controlled with a series of float switches. Dual 62,500 gallon aeration tanks are operated in
parallel and aeration is provided by three (3) positive displacement blowers and air headers with coarse bubble
diffusers. Wastewater passes from the aeration tank(s) into each of two (2) rectangular 8,333 gallon hopper -type
clarifier units. Return activated sludge (RAS) is conveyed to each aeration tank from a single air-lift pump with an
associated surface skimmer. Clarified effluent then passes to dual 35 ft2 tertiary filters with 140 cfm blowers and
525 gpm backwash pump(s) for each. During a backwash cycle, solids removed during the backwash flow to a
small mud well where float controlled, dual 90 gpm backwash surge or mud well pumps are used to return the
flow to the influent flow equalization tank.
Filtered effluent then passes through a dual bank Trojan® UV 3000PTP for disinfection, past a Hach® in -line
turbidimeter with a Honeywell® chart recorder and is then transferred to a 5.4 MG effluent storage pond by dual
89 gpm effluent pumps. If required, effluent with high turbidity is automatically diverted to a 500,000 gallon
upset pond adjacent to the WWTP. A small transfer pump is used to return any diverted water to the influent flow
equalization tank for retreatment.
Waste activated sludge (WAS) is removed from the process as needed by manually operating control valves on
the RAS recycle line and diverting flow into a single 15,000 gallon aerated sludge storage tank.
Proposed flow: 100,000 GPD
Current permitted flow: 100,000 GPD
During the last inspection, the following items were noted....
• The 5-Day Upset Pond liner has been replaced
• Five (5) new air compressors have been added to replace previously used blowers, three (3) are dedicated
for aeration basin use, the others for filter backwash and sludge digester.
• The auto-dailer has been upgraded to a newer unit with more alarm notifications
• Castle Bay Golf Course staff conducts all irrigation activities and provide records of irrigation events to
Aqua North Carolina, Inc., Aqua staff could not produce any documents of annual calibration of the
FORM: WQROSSR 04-14 Page 2 of 4

DocuSign Envelope ID: 91C9BO3F-C244-4BD5-AAEC-1B326EA5FOAF
irrigation equipment as required by the existing permit. Aqua NC staff were to investigate application
procedures and develop a calibration method.
3. Are the site conditions (e.g., soils, topography, depth to water table, etc) maintained appropriately and adequately
assimilating the waste? ® Yes or ❑ No
If no, please explain:
4. Has the site changed in any way that may affect the permit (e.g., drainage added, new wells inside the compliance
boundary, new development, etc.)? ❑ Yes or ® No
If yes, please explain:
5. Is the residuals management plan adequate? ® Yes or ❑ No
If no, please explain:
6. Are the existing application rates (e.g., hydraulic, nutrient) still acceptable? ® Yes or ❑ No
If no, please explain:
7. Is the existing groundwater monitoring program adequate? ® Yes ❑ No ❑ N/A
If no, explain and recommend any changes to the groundwater monitoring program:
8. Are there any setback conflicts for existing treatment, storage and disposal sites? ❑ Yes or ® No
If yes, attach a map showing conflict areas.
9. Is the description of the facilities as written in the existing permit correct? ® Yes or ❑ No
If no, please explain:
10. Were monitoring wells properly constructed and located? ® Yes ❑ No ❑ N/A
If no, please explain:
11. Are the monitoring well coordinates correct in BIMS? ® Yes ❑ No ❑ N/A
If no, please complete the following (expand table if necessary):
Monitoring Well
Latitude
Longitude
O / //
O / //
O / //
O / //
O //
O / II
O //
O / II
12. Has a review of all self -monitoring data been conducted (e.g., DMR, NDMR, NDAR, GW)? ® Yes or ❑ No
Please summarize any findings resulting from this review: A review of the NDMR's since 2013 indicate
occasional violations for fecal coliform, most violations were monitoring frequency violations generated from
failure to report turbiditv values over the weekend periods. this is currentiv being addressed by reportina <10
NTU if no diversion occurs.
A review of GW-59 data since 2013 indicates elevated Total Ammonia, Nitrogen (00610) in monitoring well #2
& #3 for the past several years, while BIMS flags this as a violation the current permit has no limit for this
parameter. This ammonia level is believed to be a result of the poor soils and siting of these monitoring wells.
13. Are there any permit changes needed in order to address ongoing BIMS violations? ❑ Yes or ® No
If yes, please explain:
14. Check all that apply:
® No compliance issues ❑ Current enforcement action(s) ❑ Currently under JOC
❑ Notice(s) of violation ❑ Currently under SOC ❑ Currently under moratorium
Please explain and attach any documents that may help clarify answer/comments (i.e., NOV, NOD, etc.)
Have all compliance dates/conditions in the existing permit been satisfied? ❑ Yes ❑ No ® N/A
If no, please explain:
FORM: WQROSSR 04-14 Page 3 of 4

DocuSign Envelope ID: 91C9BO3F-C244-4BD5-AAEC-1B326EA5FOAF
15. Are there any issues related to compliance/enforcement that should be resolved before issuing this permit?
❑ Yes ®No❑N/A
If yes, please explain:
IV. REGIONAL OFFICE RECOMMENDATIONS
1. Do you foresee any problems with issuance/renewal of this permit? ❑ Yes or ® No
If yes, please explain:
Hein Reason
5. Recommendation: ❑ Hold, pending receipt and review of additional information by regional office
❑ Hold, pending review of draft permit by regional office
❑ Issue upon receipt of needed additional information
® Issue
❑ Den PDIe v estate reasons: )
6. Signature of report preparer: ►MAS bin,
Signature of regional supervi
Date: 2/28/2019
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FORM: WQROSSR 04-14 Page 4 of 4

DocuSign Envelope ID: 91C9B03F-C244-4BD5-AAEC-1B326EA5FOAF
Compliance Inspection Report
Permit: WQ0018755 Effective: 05/11/07 Expiration: 04/30/16 owner: Aqua North Carolina Inc
SOC: Effective: Expiration: Facility: Castle Bay WWTP
County: Pender Castle Bay Dr
Region: Wilmington
Hampstead NC 28443
Contact Person: Joel A Mingus Title: Coastal Area Manager Phone: [phone]
Directions to Facility:
System Classifications: SI, WW2,
Primary ORC: Charles Gardner Bryan
Secondary ORC(s):
On -Site Representative(s):
Related Permits:
Certification: 1003562 Phone: [phone]
Inspection Date: 02/12/2019 Entry Time: 09:55AM Exit Time: 11:15AM
Primary Inspector: Tom Tharrington DocuSigned by: Phone:
Secondary Inspector(s):
tbk&S Tt,AY' IA46t& 2/25/2019
D7F141E73B6F3456
Reason for Inspection: Routine Inspection Type: Compliance Evaluation
Permit Inspection Type: Reclaimed Water
Facility Status: Compliant Not Compliant
Question Areas:
Miscellaneous Questions Treatment Treatment Barscreen
Treatment Filters Record Keeping Treatment Lagoons
Treatment Activated Sludge Treatment Sludge Storage/Treatment Treatment Clarifiers
Treatment Disinfection Treatment Return pumps Storage
Standby Power
(See attachment summary)
Page: 1

DocuSign Envelope ID: 91 C9BO3F-C244-4BD5-AAEC-1 B326EA5FOAF
Permit: WQ0018755 Owner - Facility: Aqua North Carolina Inc
Inspection Date: 02/12/2019 Inspection Type : Compliance Evaluation Reason for Visit: Routine
Inspection Summary:
This facility continues to improve with replacement/upgrades to several treatment components including new air
compressors, air piping and headers, new diffuser drops and diffusers. The auto -dialer has recently been upgraded to include
notifications for high turbidity, high equalization chamber level, high mudwell level, high dosing tank level and power failure.
The 5-day upset pond liner has been replaced in the last few years along with exterior painting and new control panels. The
ORC indicated the initial plans for influent screening/grit removal equipment have been discussed and this may be a possible
equipment addition in the future.
The auto -sampler used for effluent sampling is an ISCO 5800, it is a flow proportional unit taking its signal from the effluent
flowmeter. The refrigerated compartment is maintained at 3.8°C. The effluent flowmeter is an ISCO 4230 Bubbler Flow Meter
(differential pressure) and is due for a calibration check in April 2019. This is a newer unit installed in the last 2 years. The
on-line turbidimeter is an HACH 1720E low range meter and was last calibrated on October 10, 2018.
A review of the Reclaimed Water Storage Pond was conducted, and the entire dike roadway was observed, as was each of
the monitoring wells. No excessive vegetative or tree growth was affecting the pond berms and the roadway was in good
condition. All monitoring wells were accessible, labeled and locked.
The remaining issue to address at this site is the annual calibration of irrigation application equipment. While the reclaimed
water is applied to the golf course as needed by greenkeeping staff and is certainly within application limits as the course
must remain playable all season, it is a requirement to confirm these application rates. Discussions have included the
addition of a flowmeter measuring the water taken from the storage pond for irrigation purposes as being a starting point for
this application confirmation. Pump curves and line/nozzle pressure readings could also be used to calculate flowrates and
application volumes over the irrigation areas.
Additional comments are noted within the questions section of this report.
Page: 2

DocuSign Envelope ID: 91 C9BO3F-C244-4BD5-AAEC-1 B326EA5FOAF
Permit: WQ0018755 Owner - Facility: Aqua North Carolina Inc
Inspection Date: 02/12/2019 Inspection Type : Compliance Evaluation
Reason for Visit: Routine
Type
Yes No NA NE
Infiltration System
❑
Lagoon Spray, LR
❑
Recycle/Reuse
❑
Single Family Drip
❑
Activated Sludge Spray, HR
❑
Single Family Spray, LR
❑
Activated Sludge Drip, LR
❑
Activated Sludge Spray, LR
❑
Reuse (Quality)
Treatment Yes No NA NE
Are Treatment facilities consistent with those outlined in the current permit? 0 ❑ ❑ ❑
Do all treatment units appear to be operational? (if no, note below.) 0 ❑ ❑ ❑
Comment: Recently completed improvements include five new air compressors, air headers, air drops,
valves and diffusers. The exterior surfaces have been repainted and new control panels added
for the new components. The Auto -dialer notification unit has also been upgraded to a Omnisite
"Crystal Ball" unit to include more alarm points.
Standby Power Yes No NA NE
Is automatically activated standby power available? ❑ ❑ ❑
Is generator tested weekly by interrupting primary power source? ❑ ❑ ❑
Is generator operable? ❑ ❑ ❑
Does generator have adequate fuel? 0 ❑ ❑ ❑
Comment: The facility is relying on a portable generator for power if needed, the existing generator has a
low voltage issue and is scheduled to be replaced in the near term.
Treatment Barscreen Yes No NA NE
Is it free of excessive debris? ❑ ❑ ❑
Is disposal of screenings in compliance? ❑ ❑ ❑
Are the bars spaced properly? ❑ ❑ ❑
Is the unit in good condition? ❑ ❑ ❑
Comment: The barscreen unit has a manually cleaned stainless steel rack with debris drying area.
Treatment Activated Sludqe
Yes No NA NE
Is the aeration mechanism operable?
0
❑ ❑ ❑
Is the aeration basin thoroughly mixed?
0
❑ ❑ ❑
Is the aeration equipment easily accessed?
0
❑ ❑ ❑
Is Dissolved Oxygen adequate?
0
❑ ❑ ❑
Page: 3

DocuSign Envelope ID: 91 C9B03F-C244-4BD5-AAEC-1 B326EA5FOAF
Permit: WQ0018755 Owner - Facility: Aqua North Carolina Inc
Inspection Date: 02/12/2019 Inspection Type : Compliance Evaluation Reason for Visit: Routine
Are Settleometer results acceptable? 0 ❑ ❑ ❑
Is activated sludge an acceptable color? 0 ❑ ❑ ❑
Comment: The aeration basin mixed liquor appeared to have the appropriate color, density and surface
foam indicating proper operation. Settlometer results are typically 600 SV units in 30 mins. A
review of operator's records show effluent dissolved oxygen levels are within a range of 8.25
mg/I to 10.0 mg/I for the month of February. Effluent off are consistently between 7.0 to 7.5 SU.
Treatment Clarifiers Yes No NA NE
Are the weirs level? ❑ ❑ ❑
Are the weirs free of solids and algae? ❑ ❑ ❑
Is the scum removal system operational? ❑ ❑ ❑
Is the scum removal system accessible? ❑ ❑ ❑
Is the sludge blanket at an acceptable level? ❑ ❑ ❑
Is the effluent from the clarifier free of excessive solids? 0 ❑ ❑ ❑
Comment: Clarifier appeared clean with a small amount of surface "ashing" that was being adequately
removed by the surface skimmer units.
Treatment Return pumps Yes No NA NE
Are they in place? 0 ❑ ❑ ❑
Are they operational? 0 ❑ ❑ ❑
Comment: RAS pumps are all air lift pumps driven with compressed air, the RAS and surface skimmers
appeared to be adjusted to the proper return rates. A large electric mud pump with a flexible
suction hose is available to the operator for miscellaneous uses. This pump is directed to the
digester compartment for disposal.
Treatment Filters
Yes No NA NE
Is the filter media present?
0
❑ ❑ ❑
Is the filter media the correct size and type?
0
❑ ❑ ❑
Is the air scour operational?
0
❑ ❑ ❑
Is the scouring acceptable?
❑
❑ ❑
Is the clear well free of excessive solids?
0
❑ ❑ ❑
Is the mud well free of excessive solids and filter media?
❑ ❑ ❑
Does backwashing frequency appear adequate?
❑ ❑ ❑
Comment: Filters are functionina as desianed. the filter backwash is directed to the from of the treatment
system via the mudwell pumps and another portion is directed to the 5-day upset pond through
the mudwell drain valve and piping.
Treatment Sludge Storage/Treatment Yes No NA NE
Is the aeration operational? ❑ ❑ ❑
Is the aeration pattern even? ❑ ❑ ❑
If required, are Sanitary "Ts" present in tankage? ❑ ❑ ❑
Page: 4

DocuSign Envelope ID: 91C9B03F-C244-4BD5-AAEC-1B326EA5FOAF
Permit: WQ0018755 Owner - Facility: Aqua North Carolina Inc
Inspection Date: 02/12/2019 Inspection Type : Compliance Evaluation Reason for Visit:
Routine
Comment: The operator was decanting the settled sludge with an electric sump pump during the inspection.
When decanting of the sludge is no longer productive and the digester compartment is near
capacity the residuals are removed by Lewis Farms and disposed of on their permitted
application sites.
Treatment Disinfection
Yes No NA NE
Is the system working?
❑ ❑ ❑
Do the fecal coliform results indicate proper disinfection?
❑ ❑ ❑
Is there adequate detention time (-30 minutes)?
❑
❑ ❑
Is the system properly maintained?
❑ ❑ ❑
If gas, does the cylinder storage appear safe?
❑
❑ ❑
Is the fan in the chlorine feed room and storage area operable?
❑
❑ ❑
Is the chlorinator accessible?
❑
❑ ❑
If tablets, are tablets present?
❑
❑ ❑
Are the tablets the proper size and type?
❑
❑ ❑
Is contact chamber free of sludge, solids, and growth?
❑ ❑ ❑
If UV, are extra UV bulbs available?
❑ ❑ ❑
If UV, is the UV intensity adequate?
❑ ❑ ❑
# Is it a dual feed system?
❑
❑ ❑
Does the Stationary Source have more than 2500 Ibs 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? (1000--)
If yes, then when was the RMP last updated?
Comment: The UV system is maintained with monthly cleaning of bulb sleeves, during this time any bulb
issues are addressed and replaced as needed. Annually the UV units have the 12 bulbs and
sleeves replaced.
Record Keeping
Yes No NA NE
Is a copy of current permit available?
❑ ❑ ❑
Are monitoring reports present: NDMR?
❑ ❑ ❑
NDAR?
❑ ❑ ❑
Are flow rates less than of permitted flow?
❑ ❑ ❑
Are flow rates less than of permitted flow?
❑ ❑ ❑
Are application rates adhered to?
❑
❑ ❑
Is GW monitoring being conducted, if required (GW-59s submitted)?
❑ ❑ ❑
Are all samples analyzed for all required parameters?
❑ ❑ ❑
Are there any 2L GW quality violations?
❑ ❑ ❑
Is GW-59A certification form completed for facility?
❑
❑ ❑
Is effluent sampled for same parameters as GW?
❑ ❑ ❑
Page: 5

DocuSign Envelope ID: 91 C9B03F-C244-4BD5-AAEC-1 B326EA5FOAF
Permit: WQ0018755 Owner - Facility: Aqua North Carolina Inc
Inspection Date: 02/12/2019 Inspection Type : Compliance Evaluation Reason for Visit: Routine
Do effluent concentrations exceed GW standards?
❑ ❑ ❑
Are annual soil reports available?
❑
❑ ❑
# Are PAN records required?
❑
❑ ❑
# Did last soil report indicate a need for lime?
❑
❑ ❑
If so, has it been applied?
❑
❑ ❑
Are operational logs present?
❑ ❑ ❑
Are lab sheets available for review?
❑ ❑ ❑
Do lab sheets support data reported on NDMR?
❑
❑ ❑
Do lab sheets support data reported on GW-59s?
❑
❑ ❑
Are Operational and Maintenance records present?
❑ ❑ ❑
Were Operational and Maintenance records complete?
❑ ❑ ❑
Has permittee been free of public complaints in last 12 months?
❑ ❑ ❑
Is a copy of the SOC readily available?
❑
❑ ❑
No treatment units bypassed since last inspection?
0
❑ ❑ ❑
Comment: During the inspection a review of the operator readings sheets and logbook was conducted,
and
all items appeared in order.
MW-3 does continue to have exceedances for ammonia which is unusual for natural
groundwaters. It is believed this is due to the monitoring well siting and not indicative of effluent
ug ality.
Page: 6

Docu5�".
6 S E C U R E 6
Certificate Of Completion
Envelope Id: 91C9B03FC2444BD5AAEC1B326EA5FOAF
Status: Completed
Subject: Please DocuSign: CastleBay WQ0018755 StaffRpt2019.docx, CBay Inspection 2-12-19.pdf
Source Envelope:
Document Pages: 10 Signatures: 3
Envelope Originator:
Certificate Pages: 2 Initials: 0
Thomas Tharrington
AutoNav: Enabled
217 W. Jones Street
Envelopeld Stamping: Enabled
Raleigh, NC 27699
Time Zone: (UTC-08:00) Pacific Time (US & Canada)
[e-mail]
IP Address: 149.168.204.10
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Interim Regional Supervisor Wilmington Regional
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