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Home My WebLink AboutDEQp00021468A F, NCDENR North Carolina Department of Environment and Natural Resources Beverly Eaves Perdue Governor Karen Wrigley, Plant Manager Dupont -Fayetteville Works E I DuPont de Nemours and Company 22828 NC Highway 87 West Fayetteville NC 283067332 Division of Water Quality Coleen H. Sullins Director June 15, 2010 SUBJECT: June 4, 2010 Compliance Evaluation Inspection E I DuPont de Nemours and Company Dupont Fayetteville Works Permit No: NC0003573 Bladen County Dear Ms. Wrigley: Dee Freeman Secretary Enclosed please find a copy of the Compliance Evaluation Inspection form from the inspection conducted on June 4, 2010. The Compliance Evaluation Inspection was conducted by Mark Brantley, Environmental Chemist, of the Fayetteville Regional Office. The cooperation of Mr. Jamie Lewis, Facility ORC, was greatly appreciated. The facility was found to be in Compliance with permit NC0003573. As a reminder, preservation of the Waters of the State can only be achieved through consistent NPDES Permit compliance. Comments • Facility was clean and neat in appearance at the time of the inspection. 0 The November 2009 DMR and laboratory records were reviewed and appeared to be in order. Some rust was noted on both clarifiers. Please consider painting these structures as soon as possible because taking preventive maintenance steps now may avoid costly repairs in the future. Please refer to the enclosed inspection report for additional observations and comments. If you or your staff have any questions, please call me at 910-433-3327. Sincerely, Mark Brantley r ntle M.. Y Environmental Chemist Surface Water Protection Section Fayetteville Regional Office cc: Jamie Ray Lewis, ORC Central Files Fayetteville Files, (kmb) North Carolina Division of Water Quality/Aquifer Protection Section 225 Green St./ Suite 714 Fayetteville, NC 28301 Phone (910) 433-3300 FAX (910) 486-0707 Internet: h2o.enr.state.nc.us Customer Service 1-877-623-6748 An Equal Opportunity/Affirmative Action Employer - 50% Recycled/10% Post Consumer Paper NNorehCarolina aturally 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 11 NI 2 1 51 31 NC0003573 1 11 121 10/06/04 117 181 C) 19LS 201 1I Remarks 211111 11111111111111111111 11111111 IIII 1111 11111116 Inspection Work Days Facility Self -Monitoring Evaluation Rating B1 QA ---------------------------Reserved---------------------- 671 169 701 31 711 N 1 72 { N 1 73L !L_I 74 751 1 1 1 1 1 1 1 80 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 permit Number) 09:30 AM 10/06/04 07/07/01 Dupont Fayetteville Works Exit Time/Date Permit Expiration Date 22828 NC Highway 87 West Fayetteville NC 283067332 12:30 PM 10/06/04 11/10/31 Name(s) of Onsite Representative(s)/Titles(s)/Phone and Fax Number(s) Other Facility Data Jamie Ray Lewis/ORC/910-678-1143/ Name, Address of Responsible Official title/Phone and Fax Number Michael Johnson,22828 NC Highway 87 West Fayetteville NC Contacted 283067332//910-678-1155/ No Section C: Areas Evaluated During Inspection (Check only those areas evaluated) Permit E Flow Measurement Operations & Maintenance 0 Records/Reports Self -Monitoring Program 0 Sludge Handling Disposal ■ Facility Site Review 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 Mark Brantley FRO WQ//910-433-3300 Ext.727/ i 5- -'D Signature of Management Q A Reviewer Agency/Office/Phone and Fax Numbers4-1--7-10 Date Belinda S Henson FRO WQ//910-433-3300 Ext. 726/ — j --7 --1 G 4 EPA Form 3560-3 (Rev 9-94) Previous editions are obsolete. Page # 1 NPDES yr/mo/day Inspection Type 3I NC0003573 I11 12I 10/06/04 I17 18 LC Section D: Summary of Finding/Comments (Attach additional sheets of narrative and checklists as necessary) Facility was clean and neat in appearance at the time of the inspection. The November 2009 DMR and laboratory records were reviewed and appeared to be in order. Some rust was noted on both clarifiers. Please consider painting these structures as soon as possible because taking preventive maintenance steps now may avoid costly repairs in the future. Page # 2 Permit: NC0003573 Inspection Date: 06/04/2010 Owner - Facility: Dupont Fayetteville Works Inspection Type: Compliance Evaluation 1. Operations & Maintenance Yes No NA NE Is the plant generally clean with acceptable housekeeping? 0000 Does the facility analyze process control parameters, for ex: MLSS, MCRT, Settleable Solids, pH, DO, Sludge ■ ❑ ❑ C) Judge, and other that are applicable? Are records kept and maintained as required by the permit? ■ ❑ ❑ Comment: Is all required information readily available, complete and current? ■ n ❑ 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? ❑ ❑ ■ ❑ Is access to the plant site restricted to the general public? ■ ❑ ❑ ❑ Is the inspector granted access to all areas for inspection? ■ ❑ ❑ ❑ Comment: Record Keeping Yes No NA NE Are records kept and maintained as required by the permit? ■ ❑ ❑ ❑ Is all required information readily available, complete and current? ■ n ❑ ❑ Are all records maintained for 3 years (lab. reg. required 5 years)? ■ ❑ ❑ ❑ Are analytical results consistent with data reported on DMRs? ■ ❑ ❑ ❑ Is the chain -of -custody complete? ■ n ❑ ❑ 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? n ❑ ❑ ■ (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? ■ ❑ Cl ❑ 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? ■ ❑ ❑ ❑ Page # 3 Permit: NC0003573 Owner - Facility: Dupont Fayetteville Works Inspection Date: 06/04/2010 Inspection Type: Compliance Evaluation Record Keeping Yes No NA NE Facility has copy of previous year's Annual Report on file for review? ❑ ❑ ❑ ■ Comment: Flow Measurement - Effluent Yes No NA NE # Is flow meter used for reporting? ■ ❑ ❑ n Is flow meter calibrated annually? ■ ❑ ❑ ❑ Is the flow meter operational? ■ ❑ ❑ ❑ (If units are separated) Does the chart recorder match the flow meter? ❑ ❑ ❑ ■ Comment: Flow meter was last calibrated by ISI Instrumentation Services on 2-19-10. Yes No NA NE Solids Handling Equipment Yes No NA NE 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? ❑ ❑ ❑ ■ Comment: DAF unit and associated equipment was not in operation at the time of the inspection. Sludge is disposed of at the Sampson County landfill. C`hnmirMI Gnert Yes No NA NE Is containment adequate? ■ ❑ ❑ ❑ Is storage adequate? ■ ❑ ❑ ❑ Are backup pumps available? ■ ❑ ❑ ❑ Is the site free of excessive leaking? ■ ❑ ❑ ❑ Comment: Equalization Basins Yes No NA NE 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? ■ ❑ n n Page # 4 Permit: NC0003573 Owner - Facility: Dupont Fayetteville Works Inspection Date: 06/04/2010 Inspection Type: Compliance Evaluation Equalization Basins Yes No NA NE Are float controls operable? ❑ ❑ ■ ❑ Are audible and visual alarms operable? ■ ❑ ❑ n # Is basin size/volume adequate? ■ n n n Comment: Are surface aerators and mixers operational? ❑ Secondary Clarifier Yes No NA NE Is the clarifier free of black and odorous wastewater? ■ ❑ ❑ ❑ Is the site free of .excessive buildup of solids in center well of circular clarifier? ■ n n n Are weirs level? ■ ❑ ❑ ❑ Is the site free of weir blockage? ■ ❑ ❑ n Is the site free of evidence of short-circuiting? ■ ❑ ❑ ❑ Is scum removal adequate? ■ n n n Is the site free of excessive floating sludge? ■ o o n Is the drive unit operational? ■ n n n Is the return rate acceptable (low turbulence)? ■ ❑ ❑ ❑ Is the overflow clear of excessive solids/pin floc? ■ n n n Is the sludge blanket level acceptable? (Approximately'/, of the sidewall depth) ■ n n n Comment: Aeration Basins Yes No NA NE Mode of operation Ext. Air Type of aeration system Diffused Is the basin free of dead spots? 0000 Are surface aerators and mixers operational? ❑ ❑ ■ ❑ Are the diffusers operational? ■ ❑ ❑ ❑ Is the foam the proper color for the treatment process? ■ n n n 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) ■ n n n Comment: Influent Sampling Yes No NA NE # Is composite sampling flow proportional? ❑ ❑ ■ ❑ Page # 5 Permit: NCO003573 Owner - Facility: Dupont Fayetteville Works Inspection Date: 06/04/2010 Inspection Type: Compliance Evaluation Influent Sampling Yes No NA NE Is sample collected above side streams? ■ n n n Is proper volume collected? ■ n n n Is the tubing clean? IN n n n # Is proper temperature set for sample storage (kept at less than or equal to 6.0 degrees Celsius)? ■ o o n Is sampling performed according to the permit? ■ n n n Comment: Effluent Sampling Yes No NA NE Is composite sampling flow proportional? ■ n n n Is sample collected below all treatment units? ■ n n n Is proper volume collected? ■ n n n Is the tubing clean? ■ n n n # Is proper temperature set for sample storage (kept at less than or equal to 6.0 degrees Celsius)? ■ o o n Is the facility sampling performed as required by the permit (frequency, sampling type representative)? ■ n n n Comment: Upstream / Downstream Sampling Yes No NA NE Is the facility sampling performed as required by the permit (frequency, sampling type, and sampling location)? n n 0 ■ Comment: Facility is a member of the Middle Cape Fear River Basin Association. Page # 6 �U -9 10