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Home My WebLink AboutNC0025984_Compliance Evaluation Inspection_20190509DocuSign Envelope ID: 23EBA48D-6C56-4D4D-A6C5-3A19A440B242 ROY COOPER 60�crrlor K41CHAEL S. REGAN 5eerererry LINDA CULPEPPER cfrector John Condrey, Town Manager Town of Forest City PO Box 728 Forest City, NC 28043-0728 NORTH CAROL INA Environmental Quaftty May 09, 2019 SUBJECT: Compliance Inspection Report Forest City WWTP NPDES WW Permit No. NCO025984 Rutherford County Dear Permittee: The North Carolina Division of Water Resources conducted an inspection of the Forest City WWTP on 5/01/2019. This inspection was conducted to verify that the facility is operating in compliance with the conditions and limitations specified in NPDES WW Permit No. NC0025984. 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. Please review any comments listed within the summary for further consideration. If you should have any questions, please do not hesitate to contact Mikal Willmer with the Water Quality Regional Operations Section in the Asheville Regional Office at 828-296-4500 or via email at mikal.willmer@ncdenr.gov. Sincerely, EDocuSigned by: �- OBABAESEC2434B4... Mikal Willmer, Environmental Specialist I Water Quality Regional Operations Section Asheville Regional Office Division of Water Resources, NCDEQ ATTACHMENTS: Inspection Report EC: WQS-ARO Server LF Sonny Penson, ORC G:\WR\WQ\Rutherford\Wastewater\Municipal\Forest City WWTP 25984\Inspections\May 1, 2019\20190509_NC0025984_CEI �� NartF to r� bepartntertt �f Ertv 11 3 if. ironmental Qua9rty I fliU=' not Wster Fo�sa�rcps cz I �S'J .5_ TO S�annanos. No rtlr �^.a s 2S77S DocuSign Envelope ID: 23EBA48D-6C56-4D4D-A6C5-3A19A440B242 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 IF I 3 I NC0025984 111 12 I 19/05/01 I17 18 I S J 19 L G] 201 I 211111 I I I I I I II I I I I I I I I I I I I I 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 ------------------- 671 70 I I 71 I I 72 I r I 73 I I 174 751 I I I I I I I80 u 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:OOAM 19/05/01 16/04/01 Forest City WWTP 397 Riverside Dr Exit Time/Date Permit Expiration Date Forest City NC 28043 02:OOPM 19/05/01 19/07/31 Name(s) of Onsite Representative(s)/Titles(s)/Phone and Fax Number(s) Other Facility Data Barnard Norris Penson/ORC/828-248-5217/ Name, Address of Responsible Official/Title/Phone and Fax Number Contacted Charles R Summey,PO Box 728 Forest City NC 280430728//828-248-5203/ 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 Pretreatment 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 Mikal Willmer DS� Division of Water Quality//828-296-4686) 5/10/2019 Signature of Management Q A Reviewer Agency/Office/Phone and Fax Numbers Date FDoouS,gn.d by 5 / 10/2 019 p�)" EPA Form 3560-3 (Rev 9-94) Previous editions are obsolete. Page# DocuSign Envelope ID: 23EBA48D-6C56-4D4D-A6C5-3A19A440B242 NPDES yr/mo/day Inspection Type (Cont.) NCO025984 I11 121 19/05/01 117 18 ICI Section D: Summary of Finding/Comments (Attach additional sheets of narrative and checklists as necessary) Inspector Mikal Willmer, with the Asheville Regional Office, conducted a compliance evaluation inspection of the Forest City WWTP on May 1, 2019. This inspection was conducted to determine whether the facility is being operated and maintained in compliance with NPDES Permit No. NC0025984. Sonny Penson, ORC, and Jacob Hodge (Pretreatment Coordinator) were present and assisted in the inspection. Overall the facility is being operated and maintained in compliance with the permit and staff are actively working to maintain and repair aging equipment. Staff keep detailed notes within operational logbooks and all calibration records are kept on file. Sludge hauling records are also matinained within the operators logbook. Town staff are looking to have an overflow outlet to an unused basin installed in the initial splitter box to allow for automatic flow diversion when flows reach a certain level. There is also discussion of bringing two more basins back online for flow equalization as needed, if budget allows. The following items were noted during the inspection and should be considered in future budgets: 1.Equipment is beginning to show age related wear. Several of the baffles and gates throughout the facility are rusting and should be evaluated for their structural integrity. 2.Facility staff reported, due to the diameter of the secondary effluent pipe, the clarifiers back-up during heavy flow events. 3.The telescopic sludge return valve in the clarifier is broken and should be fixed to help staff more easily manage and operate the facility. 4.Generator: The generator cannot run the aerators. This should be assessed in future upgrades to prevent treatment deficiencies during an extended power outage. 5.RAS/WAS Pumps: Access to pumps is limited in a confined space and replacement requires them to be carried in/out by hand. Page# DocuSign Envelope ID: 23EBA48D-6C56-4D4D-A6C5-3A19A440B242 Permit: NCO025984 Owner - Facility: Forest City WWTP Inspection Date: 05/01/2019 Inspection Type: Compliance Evaluation 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: MLSS is analyzed twice a week and sludge blankets in clarifiers 1 and 2 are checked regularly. Permit Yes No NA NE (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? 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: Sludge dryer was phased out and is no longer in operation. Facility rescinded Class A permit and was added as a source to Southern Soil Builders Class B Permit. Five smaller first stage aeration tanks are onsite but are not currently in use. Special Condition for Expansion: ORC reports there are no current plans for expansion soon. 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 COCs 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? ❑ ❑ ❑ Page# 3 DocuSign Envelope ID: 23EBA48D-6C56-4D4D-A6C5-3A19A440B242 Permit: NCO025984 Owner - Facility: Forest City WWTP Inspection Date: 05/01/2019 Inspection Type: Compliance Evaluation Record Keeping Yes No NA NE Is the backup operator certified at one grade less or greater than the facility classification? 0 ❑ ❑ ❑ Is a copy of the current NPDES permit available on site? 0 ❑ ❑ ❑ Facility has copy of previous year's Annual Report on file for review? 0 ❑ ❑ ❑ Comment: Forest City contracts with ETS for NPDES parameters and currently PAR Laboratories out of Charlotte for all industrial sampling. Annual reports are posted on the Town's website and notifications are at the bottom of customer's bills. Flow Measurement - Influent # 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: Meter and chart recorder are calibrated twice a year. Influent flow is used for reporting. Last calibrated by KDT Service Technoloaies on Jan 2. 2019. 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? M ❑ ❑ ❑ Comment: Sampler is set to flow proportional and the temperature was 1 degree Celsius at the time of the inspection. 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? 0 ❑ ❑ ❑ Is the unit in good condition? ❑ 0 ❑ ❑ Page# 4 DocuSign Envelope ID: 23EBA48D-6C56-4D4D-A6C5-3A19A440B242 Permit: NCO025984 Owner - Facility: Forest City WWTP Inspection Date: 05/01/2019 Inspection Type: Compliance Evaluation Bar Screens Yes No NA NE Comment: There is a manual bar screen directly behind the mechanical step screen, which can cause flow to backup during heavy rain events due to debris. Facility staff hope to replace the current setup to a mechanical rake screen for easier management during heavy flows. 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: Grease Removal Yes No NA NE # Is automatic grease removal present? 0 ❑ ❑ ❑ Is grease removal operating properly? 0 ❑ ❑ ❑ Comment: Aeration Basins Yes No NA NE Mode of operation Ext. Air Type of aeration system Surface 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: There is currently one active aeration basin. The initial splitter box allows manual diversion to an inactive basin if needed during heavy flows (but not easily returned to the system). Flow can also be diverted to two additional inactive basins, but only if flow is backed up in the splitter box, due to weir placement. Facility staff are looking to adjust this in the future. DO is maintained between 1.5 to 4 mg/L. Aerators are set to cycle on and off throughout the day. Potentially looking to install submersible aerators in basin. Secondary Clarifier Yes No NA NE Page# 5 DocuSign Envelope ID: 23EBA48D-6C56-4D4D-A6C5-3A19A440B242 Permit: NCO025984 Owner - Facility: Forest City WWTP Inspection Date: 05/01/2019 Inspection Type: Compliance Evaluation 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'/4 of the sidewall depth) Yes No NA NE • ❑ ❑ ❑ • ❑ ❑ ❑ • ❑ ❑ ❑ • ❑ ❑ ❑ • ❑ ❑ ❑ • ❑ ❑ ❑ ■ ❑ ❑ ❑ ■ ❑ ❑ ❑ ■ ❑ ❑ ❑ • ❑ ❑ ❑ • ❑ ❑ ❑ Comment: Blanket was Tout of 14.5' in clarifier 1. Weirs are cleared of algae weekly during summer months. Some algae were beginning to grow back, but were not blocking weirs at the time of the inspection. The telescoping mechanism of the sludge return valves is broken. RAS discharges for approximately 22 minutes and is then off for about an hour. Aerobic Digester Yes No NA NE Is the capacity adequate? 0 ❑ ❑ ❑ Is the mixing adequate? 0 ❑ ❑ ❑ Is the site free of excessive foaming in the tank? 0 ❑ ❑ ❑ # Is the odor acceptable? 0 ❑ ❑ ❑ # Is tankage available for properly waste sludge? 0 ❑ ❑ ❑ Comment: Mixers, blowers and pumps are being updated within the digesters. Currently waste sludge is sent to digester 1, then to the belt thickener and discharged to digester #2 before being sent to the Belt filter press for further processing. The belt thickner is slated to be replaced with a rotary drum thickener according to the most recent A to C. 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? ❑ ❑ ❑ Is the contact chamber free of growth, or sludge buildup? 0 ❑ ❑ ❑ Is there chlorine residual prior to de -chlorination? ❑ ❑ ❑ 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? ❑ ❑ 0 ❑ Page# 6 DocuSign Envelope ID: 23EBA48D-6C56-4D4D-A6C5-3A19A440B242 Permit: NCO025984 Owner - Facility: Forest City WWTP Inspection Date: 05/01/2019 Inspection Type: Compliance Evaluation Disinfection -Gas Yes No NA NE If yes, then what is the EPA twelve digit ID Number? (1000- - ) If yes, then when was the RMP last updated? Comment: Facility maintains under the threshold for chlorine and sulfur dioxide. Feed is flow proportional. Building has alarms and ventilation in the event of a leak. Fire Department is contacted if a leak is detected. 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? M ❑ ❑ ❑ # Is de -chlorination substance stored away from chlorine containers? ❑ 0 ❑ ❑ Are the tablets the proper size and type? ❑ ❑ 0 ❑ Comment: Feed is flow proportional, not necessarily 1 to 1. Cylinders are stored under roof in a seDarate room from the control Danels. Chlorine and sulfur dioxide are stored in the same room. Are tablet de -chlorinators operational? Number of tubes in use? ❑ ❑ ■ ❑ Comment: Facilitv staff hope to move to a liouid feed in the future for safetv. Currentiv the only uparades approved, as of the inspection, were for the digesters. 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: All pumps are operational: however, both RAS and WAS pumps are in a confined space and there is no easy way to remove the pumps (must be carried up and down a single flight of narrow stairs). Recommend exploring options for ease of access and removal during future facility upgrades. Flow Measurement - Effluent Yes No NA NE # Is flow meter used for reporting? ❑ 0 ❑ ❑ Is flow meter calibrated annually? 0 ❑ ❑ ❑ Is the flow meter operational? 0 ❑ ❑ ❑ (If units are separated) Does the chart recorder match the flow meter? ❑ ❑ 0 ❑ Comment: Facility uses influent flow meter for reporting. Page# 7 DocuSign Envelope ID: 23EBA48D-6C56-4D4D-A6C5-3A19A440B242 Permit: NCO025984 Owner - Facility: Forest City WWTP Inspection Date: 05/01/2019 Inspection Type: Compliance Evaluation 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: No issue noted at the time of the insDection and no effluent violations noted durina the previous calendar year. 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? 0 ❑ ❑ ❑ If effluent (diffuser pipes are required) are they operating properly? ❑ ❑ 0 ❑ Comment: Diffusers are not installed. Facility has step aeration after dechlorination. 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: The Upstream sample is at the bridge 1/2 mile up the river and the downstream site is approximately 3/4s to a mile down the river. 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: Fuel is maintained onsite and contractor is used for maintenance. Generator cannot run aerators. Generator capacity should be assessed in future upgrades to prevent treatment deficiencies in the event of an extended Dower outaae. Solids Handling Equipment Yes No NA NE Page# 8 DocuSign Envelope ID: 23EBA48D-6C56-4D4D-A6C5-3A19A440B242 Permit: NC0025984 Owner - Facility: Forest City WWTP Inspection Date: 05/01/2019 Inspection Type: Compliance Evaluation Solids Handling Equipment Is the equipment operational? Is the chemical feed equipment operational? Is storage adequate? 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? Is the site free of excessive moisture in belt filter press sludge cake? The facility has an approved sludge management plan? Yes No NA NE ■ ❑ ❑ ❑ ■ ❑ ❑ ❑ ■ ❑ ❑ ❑ ❑ ❑ ❑ ■ ❑ ❑ ❑ ■ ❑ ❑ ❑ ■ ❑ ❑ ❑ Comment: Belt filter was not running at the time of the inspection. Belts were recently replaced.. Page# 9 Certificate Of Completion Envelope Id: 23EBA48D6C564D4DA6C53Al9A44OB242 Subject: Please DocuSign: 20190509_NC0025984_CEl.ltr.docx, 20190509_NC0025984_CE1.inspect. pdf Source Envelope: Document Pages: 10 Signatures: 2 Certificate Pages: 2 Initials: 1 AutoNav: Enabled Envelopeld Stamping: Enabled Time Zone: (UTC-05:00) Eastern Time (US & Canada) Record Tracking Status: Original Holder: Mikal Willmer May 10, 2019 1 09:24 Mikal.willmer@ncdenr.gov Signer Events Signature Mikal Willmer D—Signed by: mikal.willmer@ncdenr.gov Environmental Specialist °BABAEeE°2434BG'n v � North Carolina Department of Environmental Quality Security Level: Email, Account Authentication Signature Adoption: Drawn on Device (None) Using IP Address: 149.168.204.10 Electronic Record and Signature Disclosure: Not Offered via DocuSign G. Landon Davidson landon.davidson@ncdenr.gov Asheville Regional Office, Regional Supervisor DEQ, Division of Water Resources, Water Quality Regional Operatoins Security Level: Email, Account Authentication (None) Electronic Record and Signature Disclosure: Not Offered via DocuSign In Person Signer Events Editor Delivery Events Agent Delivery Events Intermediary Delivery Events Certified Delivery Events Carbon Copy Events Witness Events Notary Events Envelope Summary Events Envelope Sent Certified Delivered Signing Complete EDI-Signld by: 7E617A38285848C... Signature Adoption: Uploaded Signature Image Using IP Address: 174.196.135.223 Signed using mobile Signature Status Status Status Status Status Signature Signature Status Hashed/Encrypted Security Checked Security Checked Status: Completed Envelope Originator: Mikal Willmer 217 W. Jones Street Raleigh, NC 27699 Mikal.willmer@ncdenr.gov IP Address: 149.168.204.10 Location: DocuSign Timestamp Sent: May 10, 2019 1 09:25 Viewed: May 10, 2019 1 09:26 Signed: May 10, 2019 1 09:26 Sent: May 10, 2019 1 09:26 Viewed: May 10, 2019 1 09:38 Signed: May 10, 2019 1 09:39 Timestamp Timestamp Timestamp Timestamp Timestamp Timestamp Timestamp Timestamp Timestamps May 10, 2019 1 09:26 May 10, 2019 1 09:38 May 10, 2019 1 09:39 Docu5�". 6 S E C U R E D Envelope Summary Events Completed Status Security Checked Timestamps May 10, 2019 1 09:39 Payment Events Status Timestamps