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Home My WebLink AboutDEQp00021945r NCDENR North Carolina Department of Environment and Natural Resources Michael F. Easley, Governor August 4, 2004 Michael E. Johnson, Environmental Manager Dupont — Fayetteville Works 22828 NC Hwy 87 West Fayetteville, NC 28306-7332 Subject: Compliance Evaluation Inspection (CEI) DuPont — Fayetteville Works NPDES Permit No. NC0003573 Bladen County Dear Mr. Johnson: William G. Ross Jr., Secretary Alan W. Klimek, P.E., Director Coleen H. Sullins, Deputy Director Division of Water Quality Enclosed you will find a copy of the Compliance Evaluation Inspection (CEI) report for the inspection conducted on June 16, 2004. As part of the inspection a tour of the Wastewater Treatment Plant was conducted. All observations and recommendations are in Section D. Summary of Findings/Comments of this inspection report. Based upon the overall tour of the wastewater treatment plant, record keeping, self-monitoring/reporting, brief laboratory tour, operation of treatment units, process control, and maintenance, this facility appears to be well- maintained, and you are commended for the continued success of the wastewater treatment plant. DWQ-FRO appreciates the time and professional courtesy that was extended by your staff during the inspection. If you have any questions or comments concerning this report or require clarification on part(s) of this report, please feel free to contact me at (910) 486-1541 extension 712. Sincerely, Dale Lopez Environmental Specialist Enclosures: Brief Description of DuPont — Fayetteville Works WWTP EPA Water Compliance Inspection Report Facility Site Review (checklist) Regional Field Inspectors Check List for Field Parameters cc: Robert Geddie, ORC Nne orthCarolina 225 Green Street — Suite 714, Fayetteville, North Carolina 28301-5043 ;Vaturally Phone: 910-486-1541 \ FAX: 910-486-0707 \ Internet: www.enr.state.nc.us/ENR/ An Equal Opportunity / Affirmative Action Employer - 50 % Recycled � 10 9� Post Consumer Paper J Brief Description of DuPont — Fayetteville Works WWTP: Dymetrol (North side of plant), Butacite (West side), Nafion (East side) merged influent process and domestic flows (from the Sanitary Sewage Lift Station at Third Street and C Street) in the Collection Sump from two lines. Each line was 2 -inches in diameter, one was process and one was domestic. Also, flowing into the Collection Sump was the process wastewater from PMDF (a Teflon manufacturer located on the East side of the plant, there were 2 -inch lines for the process flow and the domestic flow). The AFPO (intermediate for Teflon) wastewater was shipped out. There was an odor in the Collection Sump area (probably due to buta-aldehyde). The influent had between 500 to 700 mg/L of BOD (90% of the BOD & COD came from the Butacite Plant) and between 1000 to 2,000 mg/L of COD. Flow could be diverted (by automatic switch -over) to a 175,000 gallon capacity Retention Tank (that handled spills and chemical slugs), and later sent back to the Collection Sump through a two-inch line. Normally, the flow was pumped to an 850,000 gallon capacity Equalization Basin (EQ), which had three aerators (40 HP each) and two mixers (20 HP each). In the EQ basin, there was recirculation through a Muffin Monster, the flow then went back to the EQ basin. The Collection Sump and the Equalization Basin were considered as the Primary Treatment Units. The Pre -Digester Tank, Aeration Tank (20 feet deep, with 3 feet of freeboard), and the Two Clarifier Tanks were considered as the Secondary Treatment Units. Flow was then pumped to an aerated Pre -Digester Tank, with a 50 horsepower (HP) aerator and a 15 HP blower. Adsorption of the hydrocarbons onto the bacteria occurred in the Pre -Digester Tank. Flow was then pumped to an Aeration Tank (where Absorption occurred), aerated by two blowers (each rated at 4,000 cubic feet per minute (CFM), one blower rated at 1,200 CFM, and one BioMixer rated at 1,600 CFM). Ammonium hydroxide (28% concentration) was used as a nitrogen nutrient source, and phosphoric acid was used for the phosphate nutrient source. Both were continuously added to the Aeration Tank. In addition, when the production plant was down and the biomass food source was low, sodium acetate was added to the Aeration Tank as a carbon source to keep the biomass in good condition. folic acid was intermittently added as a micronutrient. Flow traveled to the two circular Clarifier Tanks. #1 Clarifier Tank was 45 -feet in diatneter and 10 -feet deep. #2 Clarifier Tank was 55 -feet in diameter and 10 -feet deep. For process control, a sludge blanket of between zero to 5 feet of was maintained in each Clarifier Tank. The Return Activated Sludge (RAS) was pumped from the two circular Clarifier Tanks to the Aeration Tank. Scum that was collected from the Clarifier Tanks was pumped to the Equalization Basin. Effluent from the Clarifier Tanks flowed to a 6 -inch Parshall Flume. The Outfall 001 composite sampler was located at the Parshall Flume. Outfall 001 effluent had treated wastewaters from the Sanitary Wastewater, Demineralizer Regeneration Wastewater, Process Wastewater from the Butacite Plant Area, Process Wastewater from Nafion Area, and process wastewater from Safety Glass Plus (not started yet). Flow from Outfall 001 traveled into aboard lined ditch, which contained the boiler blow -down from Dupont oil -fired boilers, boiler blow -down, the once -through cooling water, Nafion's low biodegradable process wastewater from Outfall 006 (which is now out -of -service without flow), and filter backwash that was discharged to the Nafion ditch, which then flowed to a lined ditch. Approximately 50 to 100 feet downstream of where Outfall 001 the flow commingled with the flow that was in the Board Lined Ditch; the flow then passed under a board deck that supported the Outfall 002 compositor. For compliance monitoring of samples for chronic toxicity and according to the NPDES permit, the samples were taken downstream of the confluence of outfall 001 and 002. Waste Activated Sludge (WAS) flowed from the underflow of the two Clarifier Tanks and traveled to the Dissolved Air Floatation (DAF) Tank. The solids were pumped to a Holding Tank, then to a Feed Tank (with coagulant). The flow was thickened (with polymer addition) in the Pre -Thickener Tank (Stream addition). Solids were de -watered in the Screw Press (with Stream addition). The Total Solids analysis at this point ranged from 9 to 18%. A conveyor transferred the solids to a Hold -Up Tank, where it was mixed with lime. Solids traveled along another conveyor, then through an air and steam dryer (the air going to an Odor Scrubber and vented to the atmosphere). The dried solids were transferred onto another conveyor, to a Sludge Waste Container, and finally to the Roseboro Landfill (Waste Industries). The final day filter sludge Total Solids analysis ranged from 35 to 60%. 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 LJ 2 LJ 31 MC0003573 111 121 04/06/16 117 181,1 19('Sj 201U ' lJ - J tJ u Remarks 2111111111 11111111 11111111 11111111 1111 1111 111111166 Inspection Work Days Facility Self -Monitoring Evaluation Rating B1 QA -------------- 671 3.o 169 70 U 71 U 72 LJ 73 UJ 74 751 1 1 1 1 1 Li 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 ,4/06/16 04/02/C1 Dupont Fayetteville Works Exit Time/Date Permit Expiration Date 22828 NC Highway 87 West Fayetteville NC 28306 02:CC PN: 04/06/16 06/10/31 Name(s) of Onsite Representative(s)lTitles(s)/Phone and Fax Number(s) Other Facility Data Robert J Geddie/ORC/910-678-1219/ Name, Address of Responsible Official/Title/Phone and Fax Number Michael Johnson,22828 NC Hwy 87 W Fayetteville NC 26306//910-678-1FOred 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 Sig e(s) of Inspector(s) Agency/Office/Phone and Fax Numbers Date / i Dale Lopez „_ A , FRO WQ//910-486-154"_/910-486-0707 iK'i,� Com C!. Signature of Manageme Q A Rev' A ency/Office/Phone and Fax Numbers Date EPA Form 3560-3 (Rev 9-94) Previous editions are obsolete. NPDES yr/molday Inspection Type 1 3I NC0003573 11 121 04/06/16 17 18 U Section D: Summary of Finding/Comments (Attach additional sheets of narrative and checklists as necessary) This wastewater treatment facility appeared to be well maintained. Varmit: NC0003573 Owner - Facility: E I DuPont de Nemours and Company - Dupont Fayetteville Works Inspection Date: 06/16/04 Inspection Type: Compliance Evaluation E!=it Yes No NA NF (if the present permit expires in 6 months or less). Has the permittee submitted a new application? N ❑ ❑ ❑ Is the facility as described in the permit? 0 ❑ ❑ ❑ 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? a ❑ ❑ ❑ Comment: Qperations S Maintenance Yes No NA NF Does the plant have general safety structures in place such as rails around or covers over tanks, pits, or welts? N ❑ ❑ ❑ Is the plant generally clean with acceptable housekeeping? M ❑ ❑ ❑ Comment: Is the pump wet well free of bypass lines or structures? 0 ❑ ❑ ❑ Is the general housekeeping acceptable? M ❑ ❑ ❑ Is the wet well free of excessive grease? M ❑ ❑ ❑ Are all pumps present? 0 ❑ ❑ ❑ Are all pumps operable? 0 ❑ ❑ ❑ Are float controls operable? 0 ❑ ❑ ❑ Is SCADA telemetry available and operational? 0 ❑ ❑ ❑ Is audible and visual alarm available and operational? ❑ ❑ ❑ Comment: Bailey DCS instead of the SCADA telemetry. Equalization Yes No NA NE Basis Is aeration adequate? 0 ❑ ❑ ❑ Is the basin free of bypass lines or structures to the natural environment? 0 ❑ ❑ ❑ Is the general housekeeping acceptable? M ❑ ❑ ❑ Is the basin free of excessive grease? M ❑ ❑ ❑ Are all pumps present? M ❑ ❑ ❑ Are all pumps operable? 0 ❑ ❑ ❑ Are float controls operable? 0 ❑ ❑ ❑ Are audible and visual alarms operable? 0 ❑ ❑ ❑ Is basin sizetvolume adequate? 0 ❑ ❑ ❑ Comment: Floats are set at 11.5 feet. Is the clarifier free of black and odorous wastewater? 0 ❑ ❑ ❑ Is the site free of excessive buildup of solids in center well of circular darthert ❑ ❑ ❑ 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 sludge blanket level acceptable? ❑ ❑ ❑ Is the return rate acceptable (low turbulence)? 0 0 11 Permit: NC0003573 Owner - Facility: E I DuPont de Nemours and Company - Dupont Fayetteville Works Inspection Date: 0666104 inspection Type: Compliance Evaluation Bmwdacy dgel: Yes Is the overflow dear of excessive solids/pin floc? NoNNA_ NF N ❑ ❑ ❑ Is the surface free of bulking ? ❑ ❑ ❑ Comment: The scum went back to the chlorination pit. Aeatiion Basing, Yes No NA NF 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? N ❑ ❑ ❑ Is the DO level acceptable? 0 ❑ ❑ ❑ Are settleometer results acceptable? a ❑ ❑ ❑ Comment: This unit was an Aeration Tank instead of an aeration basin. Yes Standby! Power Is automatically activated standby power available? No NA NE E ❑ ❑ ❑ Is generator tested weekly by interrupting primary power source? ❑ ❑ ❑ ❑ Is generator tested under load at least quarterly? ❑ ❑ ❑ ❑ Was generator tested & operational during the inspection? ❑ ❑ ❑ ❑ Do the generators) have adequate capacity to operate the entire wastewater site? ❑ ❑ ❑ ❑ Does generator have adequate fuel? ❑ ❑ ❑ ❑ Is there an emergency agreement with a fuel vendor for extended run on back-up power? ❑ ❑ ❑ ❑ Comment: There are two power sources from Weatherspoon and from Duke (Progress Energy), with automatic transfer of power. Yes No NA NE I,aboratocy Are field parameters performed by certified personnel or laboratory? 0 ❑ ❑ ❑ Are all other parameters(excluding field parameters) performed by a certified lab? Cl ❑ ❑ Is the facility using a contract lab? ❑ ❑ ❑ Are analytical results consistent with data reported on DMRs? 0 ❑ ❑ ❑ Is proper temperature set for sample storage (kept at 1.0 to 4.4 degrees Celsius)? ❑ ❑ N ❑ Incubator (Fecal Coliform) set to 44.5 degrees Celsius+/- 0.2 degrees? ❑ ❑ ❑ Incubator (BOD) set to 20.0 degrees Celsius +/- 1.0 degrees? ❑ ❑ ❑ Comment: Yes No NA NE Fioy Meaj rrement -Effluent Is flow meter used for reporting? M ❑ ❑ ❑ Is flow meter calibrated annually? E ❑ ❑ ❑ Is flow meter operating properly? N ❑ ❑ ❑ (if units are separated) Does the chart recorder match the flow meter? ❑ Cl N ❑ Comment: 6-inch Parshall Fiume, calibrated twice per year by instrumentation Services, Inc. (last calibrated on 02111104) Yes No NA NE RamW Are records kept and maintained as required by the permit? N ❑ ❑ ❑ Is all required information readily available, complete and current? �Q 9 — � � ■ ❑ ❑ ❑ Are all records maintained for 3 years (lab. reg. required 5 years)? N 0 0 0 Permit: NCO003573 Owner - Facility: E 1 DuPont de Nemours and Company - Dupont Fayetteville Works Inspection Date: 06/16/04 Inspection Type: Compliance Evaluation $£t.=d. Keepica Yes Are analytical results consistent with data reported on DMRs? No N 0013 NA N Are sampling and analysis data adequate and include: 0 000 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 Plant records are adequate, available and include 0 ❑ ❑ ❑ 0&M Manual ❑ As built Engineering drawings ❑ Schedules and dates of equipment maintenance and repairs ❑ Are DMRs complete: do they include all permit parameters? ❑ ❑ ❑ Has the facility submitted its annual compliance report to users? ❑ 0 ❑ (If the facility is = or > 5 MGD permitted flow) Do they operate 24(7 with a certified operator on each shift? E ❑ ❑ ❑ Is the ORC visitation log available and current? 0 ❑ ❑ ❑ 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? 0 ❑ ❑ ❑ Is the facility description verified as contained in the NPDES permit? 0 ❑ ❑ 0 Does the facility analyze process control parameters, for example: MLSS, MCRT, Settleable Solids, DO, Sludge 0 0 11 ❑ Judge, pH, and others that are applicable? Facility has copy of previous year's Annual Report on file for review? 0 ❑ ❑ Cl Comment: As a requirement for Field Parameter Certification,15A NCAC 02H .0805 (g)(1) requires that "Data pertinent to each analysis must be maintained for five years." Yes No NA NE Effluent Sam ling Is composite sampling flow proportional? ❑ ❑ ❑ Is sample collected below all treatment units? ❑ ❑ 0 Is proper volume collected? ❑ ❑ 0 Is the tubing clean? 0 0 0 Is proper temperature set for sample storage (kept at 1 A to 4.4 degrees Celsius)? E ❑ ❑ 0 Is the facility sampling performed as required by the permit (frequency, sampling type representative)? 0 ❑ ❑ ❑ Comment: Yes No NA NE Is the facility sampling performed as required by the permit (frequency, sampling type, and sampling location)? ❑ ❑ N ❑ Comment: The Cape Fear River Association performs the sampling. Yes No NA NE Is the equipment operational? 0 ❑ ❑ 0 Is the chemical feed equipment operational? N ❑ ❑ ❑ Is storage adequate? 0 1:1 ❑ 0 Is the site free of high level of solids in filtrate from filter presses or vacuum filters? N ❑ ❑ ❑ Is the site free of sludge buildup on belts andlor rollers of filter press? N 0 ❑ ❑ Is the site free of excessive moisture in belt filter press sludge cake? 0 0 N 0 Permit: NC0003573 Owner - Facility: E I DuPont de Nemours and Company - Dupont Fayetteville Works Inspection Date: 06/16/04 Inspection Type: Compliance Evaluation Yes No NA NE Comment: Chemical Feed Yes_ No NA NF Is containment adequate? 0000 Is storage adequate? 0000 Are backup pumps available? M 0 0 0 Is the site free of excessive leaking? 0000 Comment Is right of way to the outfall property maintained? 0 0 0 0 Are receiving water free of solids and floatable wastewater materials? 0 0 0 0 Are the receiving waters free of solids / debris? M 0 11 0 Are the receiving waters free of foam other than a trace? 0 0 0 Are the receiving waters free of sludge worms? 0 0 0 If effluent (diffuser pipes are required) are they operating properly? 0 0 0 0 Comment: hO 9- IN Regional Field Inspectors Check List for Field Parameters Name of site to be Inspected: Date: Field certification # (if applicable):0 5 Inspector: NPDES #: 00 tbl)� S 73 Region: rif o 1. Circle the parameter or paramett"e}rs performed at this site. C..0 Residual Chlorine, Settleable Solids, DO, Conductivit , emperature II. Instrumentation: A. Does the facility have the equipment necessary to analyze field parameters as circled above? 1. A pH meteres No j4�1411. .s 2. A Residual Chlorine meter Yes No s - All, 3. DO meter Yes No 4. A Cone for settleable solids Yes No 5. A thermometer or meter that measures temperature. e7 No 6. Conductivity meter Yes No III. Calibration/Analysis: 1. Is the pH meter calibrated with a 2 buffers and checked with a third buffer each day of use? Yes No 2. For Total Residual Chlorine, is a check standard analyzed each day of use? Yes No 3. Is the air calibration of the DO meter performed each day of use? Yes No 4. For Settleable Solids, is 1 liter of sample settled for 1 hour? Yes No 5. Is the temperature measuring device calibrated annually against a certified thermometer? Yes No 6. For Conductivity, is a calibration standard analyzed each day of use? Yes No IV. Documentation; 1. Is the date and time that the sample was collected documented?ees No 2. Is the sample site documented? No 3. Is the sample collector documented? es No 4. Is the analysis date and time documented? es No 5. Did the analyst sign the documentation? Yes No 6. Is record of calibration documented? No 7. For Settleable Solids, is sample volume and 1 hour time settling time documented? Yes No 8. For Temperature, is the annual calibration of the measuring device documented? Yes ', No Comments: Please submit a copy of this completed form to the Laboratory Certification Program. DWQ Lab Certification Chemistry Lab Courier # 52-01-01 FIELD INSPECTOR CHECKLIST REV. 04/23/2002