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Home My WebLink AboutNC0074900_Inspection_20190603ROY COOPER Governor MICHAEL S. REGAN Secretary LINDA CULPEPPER Director Mr. Shannon V. Becker, President Aqua North Carolina, Inc. 202 Mackenan Court Cary, North Carolina 27511 Dear Mr. Becker: NORTH CAROLINA Environmental Quality June 3, 2019 Subject: Compliance Evaluation Inspection Highway 150 WWTP NPDES Permit No. NCO074900 Iredell County Enclosed is a copy of the Compliance Evaluation Inspection Report for the inspection conducted at the subject facility on May 16, 2019, by Mr. Wes Bell of this Office. Please inform the facility's Operator -in -Responsible Charge (ORC) of our findings 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 Mr. Bell at (704) 235-2192 or at wes.bell@ncdenr.gov. Sincerely, DocuSigned by: F161 FB69A2D84A3... for W. Corey Basinger, Regional Supervisor Water Quality Regional Operations Section Division of Water Resources, NCDEQ Enclosure: Inspection Report D Q � North Carolina Department of Environmental Quality I Division of Water Resources Mooresville Regional Office 1 610 East Center Avenue, Suite 301 1 Mooresville, North Carolina 28115 NORTH CAROLINA Da"MoM a enWmn�bl mwnq 704,663.1699 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 NCO074900 111 12 I 19/05/16 I17 18 I S i 19 i G i 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 ------------------- 67 2.0 70 Id I 71 [„ I 72 I I 73 I I 74 75I I I I I I I I80 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) 12:40PM 19/05/16 16/11/01 Highway 150 WWTP NC Hwy 150 Exit Time/Date Permit Expiration Date Sherrills Ford INC 28673 03:15PM 19/05/16 20/03/31 Name(s) of Onsite Representative(s)/Titles(s)/Phone and Fax Number(s) Other Facility Data Dustin Allen Hester/ORC/704-507-8535/ Name, Address of Responsible Official/Title/Phone and Fax Number Contacted Shannon V Becker,202 Mackenan Ct Cary NC 27511/President/919-653-5570/ 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 cuSigned by: 6�3�2019 Wes Bell MRO WQ//704-663-1699 Ext.2192/ e E�: 96D90=437— c S' ned by: Signature of Manag men �eviewer Agency/Office/Phone and Fax Numbers Date rfi,t" H Pa*. Andrew Pitner MRO WQ//704-663-1699 Ext.21 6.3.19 F161FB69A2D84A3... EPA Form 3560-3 (Rev 9-94) Previous editions are obsolete. Page# NPDES yr/mo/day Inspection Type (Cont.) NCO074900 I11 121 19/05/16 117 18 JCJ Section D: Summary of Finding/Comments (Attach additional sheets of narrative and checklists as necessary) LABORATORY SECTION cont'd: The operations staff must ensure that the refrigerator temperature inside the facility's office is monitored and documented (less than or equal to six degrees Celsius) in the event effluent samples are temporarily stored for future delivery to and/or pickup by the contracted laboratory. Please also note that all effluent samples must be properly preserved (on ice, chemically preserved, etc.) within 15 minutes of sample collection (Reference: 40 CFR 136.3 Table II). The ORC uses a dissolved oxygen meter equipped with a luminescence dissolved oxygen (LDO) sensor. The ORC must ensure that the LDO sensor is verified against the theoretical dissolved oxygen for the current air conditions (temperature, elevation, barometric pressure, etc.) according to the NC Wastewater/Groundwater laboratory certification approved procedure for the analyses of Dissolved Oxygen. Note: The ORC was emailed a copy of the NC approved procedure following the inspection. Page# Permit: NCO074900 Inspection Date: 05/16/2019 Owner - Facility: Highway 150 WWTP 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? M ❑ ❑ ❑ 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 last compliance evaluation inspection was performed by DWR staff on 10/25/16. 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? ❑ ❑ 0 ❑ Comment: The records reviewed during the inspection were organized and well maintained. Discharge Monitoring Reports (eDMRs) were reviewed for the period April 2018 through March 2019. No effluent limit violations were reported and all monitorina freauencies were correct. Laboratory Yes No NA NE Page# 3 Permit: NCO074900 Owner - Facility: Highway 150 WWTP Inspection Date: 05/16/2019 Inspection Type: Compliance Evaluation 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 ❑ Comment: On -site field analyses (dissolved oxygen, pH, temperature and TRC) are performed under Aqua NC's field laboratory certification #5035. Water Tech Labs (all effluent parameters except field) has also been contracted to provide analytical support. 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 ❑ ❑ ❑ representative)? Comment: The subiect Dermit reauires composite and arab effluent samDles. The samDler was collecting 400 mis. per aliquot and the internal temperature was three degrees Celsius. Monthly Aliquot verifications are performed; however, the ORC must ensure to document all monthly verifications. In addition, the ORC must ensure that the preset gallon interval between the collection of samples (aliquots) is fixed at no greater than 1/24 of the expected total daily flow at the treatment system (Permit Condition Reference: Part II, Section A Composite Sample). Operations & Maintenance Yes No NA NE Is the plant generally clean with acceptable housekeeping? M ❑ ❑ ❑ Does the facility analyze process control parameters, for ex: MLSS, MCRT, Settleable ❑ ❑ ❑ Solids, pH, DO, Sludge Judge, and other that are applicable? Comment: The facilitv appeared to be DroDerly Operated and well maintained. Process control measurements are being documented and maintained on -site. This office recommends increasing the frequency of the process control measurements (MLSS, MLVSS, PH, dissolved oxygen, etc.). The facility is equipped with a dialer -type alarm system to notify the operations staff of alarm conditions. The alarm system functioned properly during the on -site test. Page# 4 Permit: NCO074900 Inspection Date: 05/16/2019 Owner - Facility: Highway 150 WWTP Inspection Type: Compliance Evaluation Equalization Basins Is the basin aerated? Is the basin free of bypass lines or structures to the natural environment? Is the basin free of excessive grease? Are all pumps present? Are all pumps operable? Are float controls operable? Are audible and visual alarms operable? # Is basin size/volume adequate? Yes No NA NE • ❑ ❑ ❑ • ❑ ❑ ❑ • ❑ ❑ ❑ • ❑ ❑ ❑ • ❑ ❑ ❑ • ❑ ❑ ❑ • ❑ ❑ ❑ • ❑ ❑ ❑ Comment: The influent initially enters the equalization (EQ) basin prior to being pumped through the screening system and into the downstream treatment processes. A significant mat of wastewater debris was observed floating in the EQ basin. This debris mat should be removed within the near future. In addition, the permittee should investigate the feasibility of conveying all influent through the bar screen prior to entering the EQ basin. 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 ❑ ❑ Comment: The bar screen (coarse) appeared rusted and deteriorated: however. no sianificant accumulations of wastewater debris (paper, etc.) were observed in the downstream treatment processes. Note: A large wastewater debris mat was observed in the equalization basin. The ORC indicated that there are future plans being proposed to replace the bar screen. The permittee should continue with these plans to replace the bar screen within the near future. Screenings are disposed at a permitted landfill. 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 ❑ ❑ ❑ Page# 5 Permit: NCO074900 Inspection Date: 05/16/2019 Aeration Basins Is the DO level acceptable? Is the DO level acceptable?(1.0 to 3.0 mg/1) Owner - Facility: Highway 150 WWTP Inspection Type: Compliance Evaluation Yes No NA NE ■ ❑ ❑ ❑ ❑ ❑ ■ ❑ Comment: Both aeration basins were operational and in service. Sodium hvdroxide is added to maintain appropriate alkalinity/pH levels. The solids inventory in the aeration basins appeared high due to the very dark appearance of the mixed liquor and foam and the high results of the settleability tests (940 and 960 ml/L). The ORC/Permittee must ensure that an adequate sludge wasting program is implemented (via process control program, etc.) to maintain an appropriate solids inventory in the aeration basins. 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'/ of the sidewall depth) 0 ❑ ❑ ❑ Comment: 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: Both tertiary filters were operational and in service. Disinfection -Tablet Yes No NA NE Page# 6 Permit: NCO074900 Inspection Date: 05/16/2019 Owner - Facility: Highway 150 WWTP Inspection Type: Compliance Evaluation Disinfection -Tablet Yes No NA NE Are tablet chlorinators operational? 0 ❑ ❑ ❑ Are the tablets the proper size and type? 0 ❑ ❑ ❑ Number of tubes in use? 4 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 ❑ ❑ ❑ Comment: The facility is equipped with dual train tablet chlorinators. The ORC was using two tubes per tablet chlorinator. De -chlorination Yes No NA NE Type of system ? Tablet 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 ❑ Comment: Are the tablets the proper size and type? 0 ❑ ❑ ❑ Are tablet de -chlorinators operational? 0 ❑ ❑ ❑ Number of tubes in use? 4 Comment: The facility is equipped with dual train tablet dechlorinators. The ORC was using two tubes Der tablet dechlorinator. 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? Comment: The flow meter is verified annually by the ORC and was last verified on 1/22/19. Effluent Pipe 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? Yes No NA NE ■ ❑ ❑ ❑ ■ ❑ ❑ ❑ ❑ ❑ ❑ ❑ ❑ ■ ❑ Yes No NA NE ❑ ❑ M ❑ ❑ ❑ ❑ ■ ❑ ❑ ■ ❑ Comment: The effluent appeared slightly turbid with trace suspended solids and no foam. The effluent is discharged through a submerged outfall in the receiving stream. Page# 7 Permit: NC0074900 Inspection Date: 05/16/2019 Owner - Facility: Highway 150 WWTP Inspection Type: Compliance Evaluation 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: Wastewater solids are removed on an as -needed basis by a contracted company (currently Rick's Septic Service). Standby Power Is automatically activated standby power available? Is the generator tested by interrupting primary power source? Is the generator tested under load? Was generator tested & operational during the inspection? Do the generator(s) have adequate capacity to operate the entire wastewater site? Is there an emergency agreement with a fuel vendor for extended run on back-up power? Is the generator fuel level monitored? Comment: The generator is tested weekly (automatically) and placed under load monthly. Yes No NA NE ❑ ❑ ❑ ❑ ❑ ❑ ❑ ❑ ❑ ❑ ❑ ❑ ❑ ❑ ❑ ❑ ❑ ❑ ❑ ❑ ❑ Page# 8