DEQp00021971

May 24, 2006
Michael Johnson
E I DuPont de Nemours and Company
22828 NC Highway 87 West
Fayetteville NC 283067332
SUBJECT: May 18, 2006 Compliance Evaluation Inspection
E I DuPont de Nemours and Company
Dupont Fayetteville Works
Permit No: NC0003573
Bladen County
Dear Mr. Johnson:
Michael F. Easley, Governor
William G. Ross Jr., Secretary
North Carolina Department of Environment and Natural Resources
Alan W. Klimek, P.E. Director
Division of Water Quality
Enclosed please find a copy of the Compliance Evaluation Inspection form from the inspection conducted on May
18, 2006. The Compliance Evaluation Inspection was conducted by Mark Brantley of the Fayetteville Regional
Office. The facility was found to be in Compliance with permit NC0003573. The cooperation of Mr. Robert
Geddie, Grade IV ORC, was greatly appreciated. As a reminder preservation of The Waters of the State can only
be achieved through consistent NPDES compliance.
Please refer to the enclosed inspection report for additional observations and comments. If you or your staff have
any questions, please call me at 910-486-1541 Ext.727.
Sincerely,
Awk 'd"t�
Mark Brantley
Environmental Chemist
Surface Water Protection Section
Fayetteville Regional Office
cc: Robert J Geddie, ORC
Central Files
Fayetteville Files
NNoe hCarolina
aturally
North Carolina Division of Water Quality/Aquifer Protection Section 225 Green St./ Suite 714 Fayetteville, NC 28301 Phone [phone]
FAX [phone] Internet: h2o.enr.state.nc.us Customer Service 1-877-623-6748
An Equal Opportunity/Affirmative Action Employer— 50% Recycled/10% Post Consumer Paper

United States Environmental Protection Agency
Form Approved.
EPA Washington, D.C. 204W
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 U 2 15� 31 NC0003573 1 11 121 06/05/18 1 17 18 UC 19JUS 20' I
UM1_t �;J 1 I
Remarks
2111111111 1111 1111 1111 1111 11111111 1111 1111 I I I1 1116
Inspection Work Days Facility Self -Monitoring Evaluation Rating B1 QA ----- -Reserved-
671 169 70 U 3) 71 L N I 72 N I 73L_U 174 751 1 I I 1 1 11 80
=—r W
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)
01:00 PM 06/05/16
04/02/01
Dupont Fayetteville Works
Exit Time/Date
Permit Expiration Date
22828 NC Highway 87 West
Fayetteville NC 283067332
03:15 PM 06/05/18
06/10/31
Name(s) of Onsite Representative(syTiitles(syPhone and Fax Number(s)
Other Facility Data
Arnold Ray Beard/ORC/910-678-1120/
Robert J Geddie/ORC/910-678-1219/
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 Flow Measurement Operations & Maintenance Records/Reports
Self -Monitoring Program Sludge Handling Disposal Facility Site Review Compliance Schedules
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
Mark Brantley FRO WQ//910-486-1541 Ext.727/
Atoti d�
Signature of Management Q A Reviewer Agency/Office/Phone and Fax Numbers Date
5_ �S- 0(0
���w
Belinda S Henson a,�
v FRO WQ//910-486-1541 Ext.726/
EPA Form 3560-3 (Rev 9-94) Previous editions are obsolete.
Page # 1

NPDES yr/mo/day Inspection Type (cont.) 1
31 NC0003573 111 121 06/05/18 1 17 18' _'
Section D: Summary of Finding/Comments (Attach additional sheets of narrative and checklists as necessary)
The Dupont Wastewater Treatment Plant was clean and neat in appearance at the time of the inspection.
COMMENTS
Several structures in the waste treatment system appeared to have paint wor n from the surfaces. The
structures included the inside of the pre -digester tank and the outside of the retention tank.
The Bio -mixer is broken and has been removed from the aeration basin. A portable blower is being used to
supply aeration to the basin. This blower provides coarse air bubbles instead of fine bubbles like the
bio -mixer.
In a previous report dated August 16, 2005 it was recommended that enclosed thermometers be purchased
and placed in the influent and effluent samplers to ensure adequate temperature readings. A set of
enclosed thermometers was received but -they were used in laboratory equipment instead of the samplers.
Please order more enclosed thermometers and place them in the influent and effluent samplers.
Staff at the Dupont Fayetteville Works is exploring several options for relocating the effluent outfall line. The
current effluent stream is eroding the banks and depositing large amounts of sediment in the Cape Fear
River. Please relocate the effluent line as soon as possible.
Page # 2

Permit: NC0003573
Inspection Date: 05/18/2006
Owner - Facility: Dupont Fayetteville Works
Inspection Type: Compliance Evaluation
Compliance Schedules
Yes
No
NA
NE
Is there a compliance schedule for this facility?
000
❑ ❑
Is the facility as described in the permit?
❑
Is the facility compliant with the permit and conditions for the review period?
■
❑
n
❑
Comment:
Is access to the plant site restricted to the general public?
■
❑
❑ ❑
Operations & Maintenance
Yes
No
NA
_NE
Is the plant generally clean with acceptable housekeeping?
0000
❑ ❑
Dates, times and location of sampling
■
Does the facility analyze process control parameters, for ex: MLSS, MCRT, Settleable Solids, pH, DO, Sludge ■ ❑ I.] ❑
Judge, and other that are applicable?
Comment: Facility uses MLSS, pH readings, dissolved oxygen readings and sludge
blankets for process control tests.
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?
■
❑
❑ ❑
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?
■
❑
❑ ❑
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?
■
❑
❑ ❑
Page # 3

Permit: NC0003573 Owner - Facility: Dupont Fayetteville Works
Inspection Date: 05/18/2006 Inspection Type: Compliance Evaluation
Record Keeping Yes No NA NE
Is the ORC visitation log available and current? N ❑ ❑ ❑
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? E ❑ ❑ ❑
Facility has copy of previous year's Annual Report on file for review?
❑ ❑
■ ❑
Comment:
Effluent Pipe
Yes No
NA NE
Is right of way to the outfall properly maintained?
M ❑
❑ ❑
Are the receiving water free of foam other than trace amounts and other debris?
0000
If effluent (diffuser pipes are required) are they operating properly?
■ ❑
❑ ❑
Comment: See note #4 on the comment page.
Flow Measurement - Effluent
Yes No
NA NE
# Is flow meter used for reporting?
0000
Is flow meter calibrated annually?
■ ❑
❑ ❑
Is the flow meter operational?
■ ❑
❑ ❑
(If units are separated) Does the chart recorder match the flow meter?
❑ ❑
❑ N
Comment: Flow meter was last calibrated by on 2-15-06.
Solids HandlingEquipment
_._._._._.._._....._.._..._............_�q _.....P. ..... .....__..
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? ■ ❑ ❑ ❑
t
Comment: The DAF unit was not in operation at the time of the inspection due to a
clarifier being offline for the monthly cleaning. Wasting was being done str aight to the
presses.
Chemical Feed Yes No NA NE
Is containment adequate? ❑ ❑ ❑ ■
Is storage adequate? ❑ ❑ ❑ ■
Page # 4

Permit: NC0003573
Owner - Facility: Dupont Fayetteville Works
Are all pumps operable?
0000
Inspection Date: 05/18/2006
Inspection Type: Compliance Evaluation
■ ❑
❑ ❑
Is SCADA telemetry available and operational?
Chemical Feed
Yes
No
NA
NE
Is storage adequate?
❑
❑
❑
■
Are backup pumps available?
0000
Yes No
NA NE
Is the basin aerated?
Is the site free of excessive leaking?
❑
❑
❑
■
Comment:
■ ❑
❑ ❑
Are all pumps present?
■ ❑
Pum. Station - Influent
Yes
No
NA
NE
Is the pump wet well free of bypass lines or structures?
■
❑
❑
❑
Is the wet well free of excessive grease?
■
❑
❑
❑
Are all pumps present?
0000
Are all pumps operable?
0000
Are float controls operable?
■ ❑
❑ ❑
Is SCADA telemetry available and operational?
■ ❑
❑ ❑
Is audible and visual alarm available and operational?
■ ❑
❑ ❑
Comment: Alarms are tied into the computer system and is monitored by the control
room.
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?
■ ❑
❑ ❑
Are float controls operable?
■ ❑
❑ ❑
Are audible and visual alarms operable?
■ ❑
❑ ❑
# Is basin size/volume adequate?
■ ❑
❑ ❑
Comment: Alarms are tied to computer system.
Secondary Clarifier
Yes No
NA NE
Is the clarifier free of black ands 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?
■ ❑
❑ ❑
Page # 5

Permit: NC0003573 Owner - Facility: Dupont Fayetteville Works
Inspection Date: 05/18/2006 Inspection Type: Compliance Evaluation
Diffused
Is the basin free of dead spots?
■
❑
Secondary Clarifier
Yes
No
NA
NE
Is the site free of excessive floating sludge?
■
❑
❑
❑
Is the drive unit operational?
■
❑
❑
❑
Is the return rate acceptable (tow turbulence)?
■
❑
❑
❑
Is the overflow clear of excessive solids/pin floc?
■
❑
❑
❑
Is the sludge blanket level acceptable? (Approximately Y. of the sidewall depth)
❑
❑
❑
■
Comment: There was some buildup of solids in the center well of clarifier number 2
Standby Power
Yes
but it did not appear to be affecting the operation of the clarifier. Clarifier #1 was down
NA NE
Is automatically activated standby power available?
❑
❑
for cleaning. The clarifiers are drained and cleaned once a m onth.
Is the generator tested by interrupting primary power source?
❑
❑
❑ ■
Aeration Basins 1
Yes
No
NA
NE
Mode of operation
Ext.
Air
Do the generator(s) have adequate capacity to operate the entire wastewater site?
❑
Type of aeration system
Diffused
Is the basin free of dead spots?
■
❑
❑ ❑
Are surface aerators and mixers operational?'
■
❑
❑ ❑
Are the diffusers operational?
■
❑
❑ ❑
Is the foam the proper color for the treatment process?
■
❑
❑ ❑
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)
■
❑
❑ ❑
Comment: The biomixer was broken and had been removed from the aeration basin.
Portable blowers have been brought in to provide aeration to the aeration basi n.
Standby Power
Yes
No
NA NE
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?
❑
❑
❑ 0
Is the generator fuel level monitored?
❑
❑
❑ ■
Comment: Facility has two sourcesof power coming into the plant. If power is
completely lost production stops therefore no wastewater is produced.
Pumps -RAS -WAS
Yes
No
NA NE
Page # 6

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