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Home My WebLink AboutDEQp00021990CF vv n J FgQG 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 mMay 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, E 2 W-ei 90", - Mark Brantley Environmental Chemist Surface Water Protection Section Fayetteville Regional Office cc: Robert J Geddie, ORC Central Files Fayetteville Files o,y�`Qt N,Carolippa ,NEllCllfll�/ North Carolina Division of Water Quality/Aquifer Protection Section 225 Green St./ Suite 714 Fayetteville, NC 28301 Phone (910) 486-1541 FAX (910) 486-0707 Internet: h2o.enr.state.mus 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. nr/'1 Nashington, D.C. 20460 EPA 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 I NI 2 151 31 NC0003573 111 121 06/05/18 117 18I CI 19I SI 201 Remarks 211111111111111111 1111111111111111 1111 111111111116 Inspection Work Days Facility Self -Monitoring Evaluation Rating B1 QA --------------------------Reserved-------------------- 80 671 169 701 31 711 NJ 721 N I 73 L1J 74 751 1 1 1 1 1 Li 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 06/05/18 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(s)lfitles(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 N 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 Find in /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/ Agency/Office/Phone and Fax Numbers Date Signature of Management Q A R'e^vie,/wle,,r) �f►Fn/ _ Belinda S Henson�t�I ' .DC7' / f�iLT� FRO W4//910 486-1541 Ext .726/ EPA Form 3560-3 (Rev 9-94) Previous editions are obsolete. Page # 1 NPDES yr/mo/day Inspection Type 3I NC0003573 11 12I 06/05/18 17 181 J (cont.) 1 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 ap pearance at the time of the inspection. COMMENTS Several structures in the waste treatment system appeared to have paint worn 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 Compliance Schedules Is there a compliance schedule for this facility? Owner - Facility: Dupont Fayetteville Works Inspection Type: Compliance Evaluation Is the facility compliant with the permit and conditions for the review period? Comment: ■nnn ■nnn Operations &Maintenance Yes No NA NE Is the plant generally clean with acceptable housekeeping? ■ n n n Does the facility analyze process control parameters, for ex: MLSS, MCRT, Settleable Solids, pH, DO, Sludge ■ n n n 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? ■ n n n Is the facility as described in the permit? ■ nnn # Are there any special conditions for the permit? ■ ❑ Cl n Is access to the plant site restricted to the general public? ■ Cl n n Is the inspector granted access to all areas for inspection? ■ n n n Comment: Record Keeping Yes No NA NE Are records kept and maintained as required by the permit? ■ ❑ ❑ n Is all required information readily available, complete and current? ■ 000 Are all records maintained for 3 years (lab, reg. required 5 years)? ■ n n Cl Are analytical results consistent with data reported on DMRs? ■ n n n Is the chain -of -custody complete? ■ 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 ■ Are DMRs complete: do they include all permit parameters? ■ n n n Has the facility submitted its annual compliance report to users and DWQ? ■ n Q n (If the facility is = or > 5 MGD permitted flow) Do they operate 24/7 with a certified operator on each shift? ■ n n n Page # 3 Permit: NC0003573 Inspection Date: 05/18/2006 Owner - Facility: Dupont Fayetteville Works Inspection Type: Compliance Evaluation Record Keeping Yes No NA NE Is the ORC visitation log available and current? ■ n n ❑ Is the ORC certified at grade equal to or higher than the facility classification? ■ n n n 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? ■ ❑ ❑ Cl Facility has copy of previous year's Annual Report on file for review? n n ■ n Comment: Effluent Pipe Yes No NA NE Is right of way to the outfall properly maintained? , ■ ❑ n Cl Are the receiving water free of foam other than trace amounts and other debris? Cl ■ ❑ ❑ 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? ■ ❑ ❑ ❑ Is flow meter calibrated annually? ■ n n ❑ Is the flow meter operational? ■ ❑ ❑ ❑ (If units are separated) Does the chart recorder match the flow meter? ❑ ❑ ❑ ■ Comment: Flow meter was last calibrated by on 2-15-06. SolidsHandlina.Equipment Yes No NA NE Is the equipment operational? ❑ ■ ❑ ❑ Is the chemical feed equipment operational? ■ ❑ ❑ ❑ Is storage adequate? ■ ❑ ❑ Cl Is the site free of high level of solids in filtrate from filter presses or vacuum filters? ■ Cl ❑ Cl Is the site free of sludge buildup on belts and/or rollers of filter press? ■ n n n Is the site free of excessive moisture in belt filter press sludge cake? ■ ❑ ❑ ❑ The facility has an approved sludge management plan? ■ n n n r 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? 13000 Is storage adequate? n n n ■ Page # 4 Permit: NC0003573 Inspection Date: 05/18/2006 Chemical Feed Is storage adequate? Are backup pumps available? Is the site free of excessive leaking? Comment: Pump Station _Influent Is the pump wet well free of bypass lines or structures? Is the wet well free of excessive grease? Are all pumps present? Are all pumps operable? Are float controls operable? Is SCADA telemetry available and operational? Owner - Facility: Dupont Fayetteville Works Inspection Type: Compliance Evaluation 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 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 Is the clarifier free of black and 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? Yes No NA NE ■nnn ■nnn ■❑❑❑ ■n❑n ■❑❑❑ ■nnn ■❑❑❑ ■nn❑ Yes No NA NE ■nnn n■nn ■nnn ■nnn ■❑n❑ Page # 5 Permit: NC0003573 Inspection Date: 05/18/2006 Owner - Facility: Dupont Fayetteville Works Inspection Type: Compliance Evaluation Secondary Clarifier res No NA NE Is the site free of excessive floating sludge? ■ ❑ ❑ ❑ Is the drive unit operational? ■ ❑ ❑ ❑ Is the return rate acceptable (low turbulence)? ■ ❑ ❑ ❑ Is the overflow clear of excessive solids/pin floc? ■ ❑ ❑ ❑ Is the sludge blanket level acceptable? (Approximately % of the sidewall depth) ❑ ❑ ❑ ■ Comment: There was some buildup of solids in the center wel I of clarifier number 2 ■ Comment: Facility has two sourcesof power coming into the plant. If power is but it did not appear to be affecting the operation of the clarifier. Clarifier #1 was down completely lost production stops therefore no wastewater is produced. for cleaning. The clarifiers are drained and cleaned once a m onth. Yes No NA NE Aeration Basins l Yes No NA NE Mode of operation Ext. Air 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 mgA) ■ ❑ ❑ ❑ Comment: The biomixer was broken and had been removed from the aeration basin. Is there an emergency agreement with a fuel vendor for extended run on back-up power? ❑ ❑ Portable blowers have been brought in to provide aeration to the aeration basi n. ■ is the generator fuel level monitored? Standby Power Yes No NA NE Is automatically activated standby power available? ❑ ,❑ ❑ ■ Is the generator tested by interrupting primary power source? ❑ 0 ❑ ■ 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: 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 "• tr n r . , �i