DEQp00021570

f-
i4 CDENR
North Carolina Department of Environment and Natural Resources
Michael F. Easley, Governor December 27, 2001 Will G. Ross Jr., Secretary
Gregory J. Thorpe, Ph.D.
Mr. Michael Johnson, Environmental Manager Acting Director
E. I. Dupont de Nemours & Company, Inc. Division of Water Quality
22828 NC Hwy. 87 West
Fayetteville, NC 28306
SUBJECT: Compliance Evaluation Inspection
E. I. Dupont de Nemours & Company, Inc.
Wastewater Treatment Plant
NPDES Permit No. NC0003573
Bladen County
Dear Mr. Johnson:
Enclosed is a copy of the Compliance Evaluation Inspection conducted December December 13.2001.
As part of the inspection a tour of the Wastewater Treatment Plant was conducted. All observations
and recommendations are in Part D. Summary of Findings/Comments of this inspection report. The
cooperation of Mr. Robert Geddie, Grade IV ORC was greatly appreciated. During the inspection
a copy of the NPDES Compliance Reminders were reviewed and left with facility staff. As a
reminder preservation of the Waters of the State can only be acquired through consistent NPDES
permit compliance.
Please review the attached report. If you or your staff have any questions do not hesitate
to contact me at 910-486-1541.
Sincerely,
,�2 r
�'rc%)�tiC?L'
Belinda S. Henson
Environmental Chemist
/bsh
Enclosures
cc: Mr. Robert Geddie, ORC, E. I. Dupont
Fayetteville Regional Office
225 Green Street - Suite 714, Fayetteville, North Carolina 28301-5043
Phone: [phone] FAX: [phone]Internet: www.enr.state.nc.us/ENR

NPDES COMPLIANCE INSPECTION REPORT
z rx North Carolina Division of Water Quality
! WjM Fayetteville Regional Office
I
SectionA. National Data System Coding
Transaction Code: N NPDES NO. NC0003573 Date: 011213
Inspector: S Facility Type: 2
Facility Evaluation Rating: 4 BI: N QA: N
Section B: Facility Data
Name and Location of Facility Inspected:
E. I. Dupont de Nemours WWTP
Entry Time/Date: 9:50am/011213
Exit Time/Date: 1:OOpm/011213
Name(s), Title(s) of On -Site Representative(s):
Robert Geddie - (Certified Grade M - "ORC"
Phone Number(s): [phone]
Name, Title and Address of Responsible Official:
Mr. Michael Johnson, Environmental Manager
22828 NC Hwy. 87 West
Fayetteville, NC 28306
Section C: Areas Evaluated During Inspection
3
Inspection Type: C
Reserved:
Reserved:
Permit Effective Date:. 001101
Permit Expiration Date: 011031
Contacted: no

Johnson
Page 3
December 27, 2001
Section D• Summary of Findings/Comments:
The wastewater facility furnishes treatment to the following industries: PMDF, Dymetrol, Nation, and
Butacite. Mineral by products from the water tkatment system is also discharged into the WWTP. All
the industries are owned by Dupont with the exception of Dymetrol.
2. Approximately 20,000 gallons per day of domestic wastewater is discharge into the treatment works.
All wastewater enters the head of the plant by gravity. Four (4) influent pumps are onsite to bring the
flow into the plant.
3. Ammonia and Phosphoric acid are added each day as a food source to enable the bacteria to live and
reproduce.
4. The flow travels from the Headworks to the aerated pre -digester tank. The tank appeared to be
operational. The flow normally travels to the EQ basin first but the facility is troubleshooting high pHs
and are not using the EQ basin at this time.
5. The waste stream flows from the pre -digester tank to the aeration tank forjurther treatment. The
diffused air system in the aeration tank appeared to be operating adequately. A Biomizer which mixes
and adds air in an area where the flow enters the tank was not operational. It is presently under repair.
The most recent Mixed Liquor Suspended Solids (M SS) result for December 13, 2001 was 3683 mg/L.
The MLSS goes into a preaeration tank where excess oxygen is taken out. This part of the treatment
assists in keeping solids from floating on the surface of the clarifiers.
6. Clarifier #1 and Clarifier #2 appeared to be operational. An antifoam agent is added to the clarifiers
to eliminate foaming problems. Polymer is also added when needed to as4ist with solids settling.
Clarifiers are taken out of service monthly for maintenance and repair.
7. The effluent appeared to be free of solids. The effluent outfall is easily accessible from the area near
the William O. Huske Lock and Dam #1.
8. The effluent composite sampler temperature appeared to be adequate at 4 degrees C. The acceptable
temperature range samples during storage and for stored sample extracts, is 1.0 - 4.4 degrees C. The
effluent sampler tubing for pipes 001(process wastewater) and 002 (cooling water) combined appeared
to have some solids or algae buildup in it. Increase in frequency of changing the tubing could enhance
the quality of the composite sample.
9. The effluent flow meter was calibrated May 10, 2001 by "Water and Waste Technical Services". It is
advisable that the flow meter calibration document contain the % error before, and after calibration in the
future by the technician.

Johnson
Page 4
December 27, 2001
10. Solids are wasted to the DAF unit and then to the sludge thickener and finally to the sludge filter press.
The DAF unit was not operating at the time of the inspection but repairs were going to be implemented
immediately as per staff. Polymer is added to the biosolids before they enter the press to assist with
dewatering. Solids content leaving the press are between 11 and 12 %. From the press, solids are dried
and lime is added and treatment of biosolids are complete. Biosolids leaving the oven are between 40
and 60% solids. I
11. Sludge disposal is by "Waste Industries" which transports the dried biosolids to their landfill in
Roseboro (Sampson County).
12. All maintenance records are on computer and documentation is incorporated by the Powerhouse
(Utilities) division of this facility which is located onsite.
13. As Built engineering drawings and 0 & M manuals are located at the Powerhouse as per Mr. Geddie.
14. The facility's present permit expired October 31, 2001. They have applied for renewal and will continue
to operate under the present permit until a new one is submitted to the facility.
15. "Simalab" analyzes all NPDES permit required parameters with the exception of the pH and
Temperature which are done by facility staff.
16. Laboratory records were reviewed for the months February and April 2001 andcompared to Discharge
Monitoring Reports. All records reviewed appeared to be accurate.
17. A compliance evaluation analysis report for the period September 2000 through August 2001 revealed
a monthly BOD violation in February 2001. A Notice of Violation (NOV) was submitted to the facility
for the BOD violation.

Name and Signature of Inspector
Belinda S. Henson
Name and Signature of Reviewer
Paul E. Rawls
Agency/Office/Telephone Date
DENR/Fayetteville/[phone] 13, :z7 -6l
q
Agency/Office/Telephone 'Date
DENR/Fayetteville/(910)4 8 6-1541
Regulatory Office Use Only
Action Taken Compliance Status
Noncompliance
_Compliance
M
e
Date

t( tr�ptalf� jn.,JJ4
&V O ARS
No
N/A
1.
t ySectian D: Sum M.W of Findings/Comments
Yes
No
�&
'Description:
Standby power or other equivalent provision provided.
a. Manual
Yes
Bne N'a&'I
N/A
b. Mechanical
Yes
The WWTP consists of equalization, neutralization,
aerated pre -digester
tank, a nutrient feed
system an aeration tank, dual
clarifiers effluent
flow measurement,
a DAF unit* a rotary filter for
sludge thickening, a sludge filter
press and steam
heated sludge dryers
(001); boiler blowdown
Yes
No
&A
a. Excessive organic content in the grit chamber
from Dupont oil -fired boilers,
boiler blowdown
and cooling tower blowdown
from BCH Energy
Project, once through cooling
water, treated wastewater
effluent from
Outfall 001. Nafion low
biodegradable process wastewater
from Outfall
(006), and filter backwash
discharge (002)_
FACILITY SITE REVIEW
Qe
No
N/A
1.
Treatment units properly operated and maintained.
Yes
No
�&
2.
Standby power or other equivalent provision provided.
Yes No N/A. 3. Adequate alarm system for power or equipment failure available.
4. Sludge disposal procedures appropriate:
C No N/A a. Disposal of sludge according to regulations
CYC No N/A b. State approval for sludge disposal received.
Yes No N/A 5. Sufficient sludge disposed of to maintain treatment process equilibrium.
(Yes`; No N/A 6. The ORC and Backup Operator are officially designated with
NCDENR/DWQ Training and Certification Unit.
(des.) No N/A 7. Adequate spare parts and supplies inventory maintained.
(Yes`; No N/A 8. Plant has general safety structures such as rails around or covers over
tanks, pits, or wells.
'es No
N/A 9.
Plant is generally clean, free from open trash areas.
10.
Screening:
Yes
NoTI/A
a. Manual
Yes
No
N/A
b. Mechanical
Yes
No
N/A
c. Buildup of debris t.
Yes
No
N/A
gid. Screenings properly disposed of.
11.
Grit Removal:
Yes
No
&A
a. Excessive organic content in the grit chamber
Yes
No
N/A
b. Excessive odors
Yes
No
N/A
c. Grit properly disposed of.

Page
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
12.
No (S1W'
No N/A
No N/A
No N/A
No N/A
No N/A
No N/A
No N/A
No N/A
No. N/A
No (
No N/A
No N/A
No N/A
No N/A
No N/A
No N/A
No N/A
Yes (X6,) N/A
Yes No
Yes qT6
N/A
Yes Wo
N/A
Yes %ia%
N/A
Yes W
N/A
Yes eo
N/A
Primary clarifier:
a. Excessive gas bubbles
b. Black and odorous wastewater '
c. Poor suspended solids removed
d. Excessive buildup of solids in center well of circular clarifier
e. Weirs level
f. Weir blockage
g. Evidence of short circuiting
h. Lack of adequate scum removal
i. Excessive floating sludge
j. Broken sludge scraper.
13. Trickling Filter:
a. Trickling filter ponding(indieating clogged media)
b. Leak at center column of trickling filter's distribution arms
c. Uneven distribution of flow on trickling filter surface
d. Uneven or discolored growth
C. Excessive sloughing of growth
f. Odor
g. Clogging of trickling filter's distribution arm orifices
h. Filter flies, wornis, or snails.
14. Activated Sludge Basins/Oxidation Ditches:
a. Dead spots
b. Failure of surface aerators
c. Air rising in clumps
d. Dark foam or bad color
e. Thick billows of white, sudsy foam
f. Air rising unevenly
g. Excessive air leaks in compressed air piping.
15. Stabilization Ponds/Lagoons:
Yes No�T1k a. Excessive weeds including duckweed in stabilization ponds
Yes No N/A b. Dead fish or aquatic organisms
Yes No. N/A c. Buildup of solids around influent pipe
Yes No N/A d. Excessive scum on surface.

4
{�yF Secondary Clarifier:
a. Excessive gas bubbles on surface
Yes a N/A b. Level overflow weirs
Yes ltd N/A c. Weir blockage
Yes eb N/A d. Evidence of short circuiting
Yes N/A e. Excessive buildup of solids in center well of circular clarifier
Yes Q N/A f. Pin floc in overflow
Ce No N/A g. Effective scum rake
Yes <�b N/A h. Floating sludge on surface
Yes Cb2 N/A i. Excessive high sludge blanket
Yes Ttj,, N/A j. Clogged sludge withdrawal ports on secondary clarifier.
Yes No FI - 19. Ultraviolet radiation disinfection present and in use.
_ 20. Dechlorination:
Yes No (&7A' a. Proper storage of sulfur dioxide cylinders
Yes No N/A b. Adequate ventilation of sulfur dioxide feeding room
Yes No N/A c. Automatic sulfur dioxide feed or feedback control operating
properly.
17. Filtration:
Yes
No
SIA
a.
Filter surface clogging
Yes
No
N/A
b.
Short filter run
Yes
No
N/A
c.
Gravel displacement of filter media
Yes
No
NCA
d.
Loss of filter media during backwashing
Yes
No
N/A
e.
Recycled filter backwash water in excess of 5 percent
Yes
No
N/A
f.
Formation of mudballs in filter media.
18. Chlorination Unit:
Yes
No
a.
Sludge buildup in contact chamber
Yes
No
N/A
b.
Gas bubbles
Yes
No
N/A
c.
Floating scum and/or solids
Yes
No
N/A
d.
Adequate ventilation of chlorine feeding room and storage area
Yes
No
N/A
e.
NIOSH -approved 30 minute air pack
Yes
No
N/A
f
All standing chlorine cylinders chained in place
Yes
No
N/A
g.
All personnel trained in the use of chlorine
Yes
No
N/A
h.
Proper chlorine feed, storage, and reserve supply.
Yes No FI - 19. Ultraviolet radiation disinfection present and in use.
_ 20. Dechlorination:
Yes No (&7A' a. Proper storage of sulfur dioxide cylinders
Yes No N/A b. Adequate ventilation of sulfur dioxide feeding room
Yes No N/A c. Automatic sulfur dioxide feed or feedback control operating
properly.
21. Aerobic Digester:
Yes
No
N/A
a. Excessive foaming in tank
Yes
No
N/A
b. Noxious odor
Yes
No
N/A
c. Mechanical aeration failure
Yes
No
N/A
d. Clogging of diffusers.

Page 4
Yes No (:SZX
Yes No N/A
Yes
No CA
Yes
No
Yes
No
Yes
No QrA
Yes
No (93
es,,
No N/A
Yes
No 0 i/A
22. Anaerobic Digester:
a. Floating cover tilting
b. Gas burner operative
23. Sludge Drying and/or disposal:
a. Poor sludge distribution on drying beds
b. Vegetation in drying beds
c. Dry sludge remaining in drying beds
d. Dry sludge stored on site
e. Filtrate from sludge drying beds returned to front of plant
f. Sludge disposal through county landfill. Sc mfson Cou ni y
g. Sludge land applied.
24. Filter Press:
Yes 40 N/A a.. High level of solids in filtrate from filter presses or vacuum filters
Yes 40 N/A b. Thin filter cake caused by poor dewatering
Yes (96 N/A c. Sludge buildup on belts and/or rollers of filter press
Yes QB N/A d. Excessive moisture in belt filter press sludge cake.
25. Polishing Ponds or Tanks:
Yes No a. Objectionable odor, excessive foam, floating solids, or oil sheens on
water surface
.,Yes No N/A b. Solids or scum accumulations in tank or at side of pond
Yes No N/A c. Evidence of bypassed polishing ponds or tanks because of low
capacity.
25. Plant Effluent:
Yes 01 N/A a. Excessive suspended solids, turbidity, foam, grease, scum, color, and
other macroscopic particulate matter present
Yes T > NIA b. Potential toxicity (dead fish, dead plant at discharge)
i�Y`e' No N/A c. Outfall discharge line easily accessible.
'e"''s No
N/A
Yes No
N/A
Yes (S2
N/A
Yes C T6
N/A
Yes No
-Yes (R&
N/A
Yes No
N/A
27,
1
Flow Measurement:
a. Proper placement of flow measurement device
b. Flow meter calibrated
c. Buildup of solids in flume or weir
d. Broken or cracked flume or weir
e. Clogged or broken stilling wells
f. Weir plate edge corroded or damaged
g. Flow measurement error less than 10%.

Page WA in Ala
ire i,A ling and analysis completed on parameters specified by permit
est NO eppi� osite sam le temperatures maintained at 4 de rees Celsius or
4z 13119 P p g
less (but above freezing) during sampling
9 No N/A c. Contract laboratory used for sample analysis
� No N/A d. Effluent composite samples obtained are flow proportional.
RECORDKEEPING AND REPORTING
'Yes ' No N/A 1. Records and reports maintained as required by permit.
Ies3 No N/A I. All required information available, complete, and current.
Yes No N/A 3. Records maintained for 3 years and all sludge records maintained for 5
years.
's✓s� No N/A 4. Analytical results consistent with data reported on DMRs.
5. Sampling and analyses data adequate and include
Yes
No
N/A
a.
Dates, times, and location of sampling
Yes
No
N/A
b.
Name of individual performing sampling
Yes
No
N/A
c.
Results of analyses and calibration
Yes
No
N/A
d.
Dates of analyses
Yes
No
N/A
e.
Name of person performing analyses.
6. Monitoring records adequate and include:
Yes No N/A a. Monitoring charts kept for 3 years
Yes No -N/A b. Flowmeter calibration records kept for 3 years.
Yes No N/A
CV -S No N/A.
Les,) No N/A
7. The pH meter is calibrated daily with two buffers and checked with a
. third buffer and properly documented.
8. Expiration dates of pH buffers adequate.
9. JI thermometers used in NPDES permit reporting is calibrated
annually with an NIST certified thermometer or a traceable
r thermometer annually and documented.
10. The following NPDES permit required parameters are analyzed on site:
pH, Temperature, Dissolved Oxygen and Chlorine Residual.

Pace 6
Yes No O°,, 11. The NPDES permit required parameter Total Chlorine Residual is
analyzed by approved method.
Yes NoNFX> l?. .BOD incubator temperature maintained at 20 +/- I Degrees Celsius
and the temperature maintained in a log for every day of operation.
Yes NoN/TN' 13. Fecal coliform incubator maintained at 44.5 +/- 0.2 Degree Celsius and
the temperature maintained in a log for every day of operation.
14. Plant records adequate and include:
Yes
No
N/A
a. O & M Manual
Yes
No
N/A
b. "As -built" engineering drawings
Yes
No
N/A
c. Schedules and dates of equipment maintenance repairs
Yes
No
N/A
d. Equipment data cards.
Yes No N/�
15.
Permittee is meeting compliance schedule.
(Ye§D No N/A
16.
DTTVIRs complete and include all NPDES permit required parameters.
Yes No 1V
17.
The facility has a permitted flow greater than 5 MGD and is required
to operate seven days per week 24 hours a day.
Yep' No N/A
18.
ORC visitation logs available and current.
Yev No N/A
19.
ORC certified at a level equal to or greater than the classification of.
the wastewater facility.
'egg No N/A
20.
Backup Operator certified at one level less than the classification of
the wastewater facility or greater. °
Yes No N/A
21.
o
Current copy of the complete NPDES permit on site.
(yes) No N/A
2'2., '
Facility description verified as contained in NPDES permit.
Yes oto N/A
Facility analyzes process control parameters for example: MLSS,
y2
MCRT, Settleable Solids and others that are applicable.
Yes No /
24.
Industrial Waste Surveys (IWS) sent to all possible Significant
Industrial Users (SIUs) within the last five years (especially new
industries).
Revised 7/16/01
by Belinda Henson