AQ_F_0900009_20140114_CMPL_CmpltRpt

Complaint Investigation Report County: Bladen
Region: FRO
NC Dept. of Environment&Natural Resources Suspect: DuPont Company -Fayetteville Works
Facility ID# 0900009
15164
Division of Air Quality
Record # 15164
Regional Investigator: Reeves, Gregory Suspect: DuPont Company-Fayetteville Works
Regional Co-investigator: Suspect Contact: Ellis H. McGaughy
Non-DAQ Investigator: Physical Location: 22828 NC Highway 87 West-
Fayetteville
Date Complaint Received: 10/31/2013 Mailing Address: 22828 NC Highway 87 West
Received By: Reeves, Gregory City/State/Zip: Fayetteville NC 28306
Date assigned: 10/31/2013 Telephone: [phone]
Alternate Telephone:
Investigation date: 11/01/2013 Complainant: Gregory Reeves
Follow-up date: 01/14/2014 Complainant Address:
Report submit date: 01/14/2014 City/State/Zip: NC
Telephone(H):
Complaint type: OTHER Telephone(W): [phone]
Complaint description: Release of unknown Call Back Required? No Response Requested
quantity of dichloromethane(methylene chloride)
from a process tower at the DuPont facility. The
release was reported to the NRC at 3:35 PM on
10/31/2013 by Mike Johnson of DuPont.
Referral to DAQ: EPA
Situation Dangerous: No Violation documented: No
Occurring Now: No NCFSPermit: N/A
Signature: 40! �I Report Date:
Comments/Directions:
DuPont Company-Fayetteville Works is located on NC Highway 87 in Bladen County. From FRO, take
Highway 87 south. The entrance to the facility is approximately 18 miles from FRO on the left side of Highway
87 just before the Cumberland/Bladen County line.
Summary of investigation:
11/01/13—Mike Johnson left a telephone voice message to Greg Reeves of FRO at 08:18 AM, reporting an
estimated 600 pound release of methylene chloride (dichloromethane) coolant. The leak appears to have lasted
less than one hour. Some of the material was captured in a below-ground sump, but some was released to the
atmosphere. Based on preliminary estimates, it appears that the release exceeds the 2D .1100 toxics limitations

in the permit(24.85 lb/hr). One employee was seriously injured and taken to a hospital for treatment of severe
frostbite. No additional information was available.
9:00 AM 11/01/13 - Greg Reeves called Mike Johnson to discuss the incident. No additional information was
available at that time. Mr. Reeves requested that a copy of the incident investigation be forwarded to FRO when
completed. In addition, a formal letter documenting the release is required to be sent to the Regional
Supervisor,DAQ, within 15 days after the incident, as this appears to be a deviation of the toxics emission
limitations under 2D .l 100 in the air permit.
11/11/13—FRO received a letter from DuPont documenting the excess emissions on 10/31/13. The report
stated that approximately 1,181 pounds of methylene chloride was unaccounted for, and that it was assumed to
be vented to atmosphere through the Nafion®Polymers Process Stack(ID No.NEP-G)during a 1-hour period.
This emission exceeds the permitted toxic emission rate of 24.85 pounds per hour in the current air permit under
2D .1100.
Mr. Johnson stated that the employee involved in the incident is still in the hospital, and has been placed in a
medically-induced coma while undergoing treatment for his injuries. He has not been interviewed as of this
date,and the investigation of the incident is still ongoing. No basic cause has yet been determined for the
release.
12/04/13—Greg Reeves spoke with Mike Johnson regarding the release. The investigation is still ongoing. The
injured employee is still in the hospital in a medically-induced coma, so has still not been interviewed regarding
the incident.
01/14/14—Greg Reeves spoke with Mike Johnson. Mr. Johnson indicated that although the incident
investigation is still not complete, it appears that the incident was not the result of a malfunction. It appears that
an employee action caused this release.
Incident investigation completed 01/14/14

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INCIDENT DESCRIPTION SAYS THE RELEASE IS COMING FROM A "TOWN",
THE RELEASE IS COMING FROM A "TOWER" OR BUILDING AT THE
FACILITY.
*** END NOTIFICATION UPDATE ALERT REPORT # 1064549 ***
Report any problems by calling 1-800-424-8802
http://www.nrc.uscg.mil
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DU f a17 I DuPont Chemicals&Fluoroproduats
® Fayetteville Works Plant
22823 NC Hwy 87 West
Fayetteville,NC 28306-7332
CFRTIFIFD MAIL ARTICLE NUMBER 7007 0710 00051455 9218
RETURN RECEIPT REQUESTED
November 11, 2013
Mr•. Steven F. Vozzo
NCDENR—Division of Air Quality
Fayetteville Regional Office
225 Green Street—Suite 714
Fayetteville,NC 28301
SUBJECT: Title V Air Quality Permit Deviation and Excess Emissions
DuPont Company—Fayetteville Works
Air Quality Permit No. 03735T37
Facility ID: 0900009, Fayetteville, Bladen County
Dear Mr, Vozzo:
Pursuant to Part I Section 3(I.A)(2)(a) and Section 3(I.A.)(3)(a) of the subject Title V
permit, this Ietter is the required notification of excess emissions and a state-enforceable-
only permit deviation of an emissions limitation for methylene chloride specified in Part I
Section 2.2(B)(1) of the subject permit, which is the rule regulating North Carolina toxic
air pollutant emissions per ISA NCAC 2D .1100• That limitation sets a facility-wide
emission limit of 24.85 pounds of inethylene chloride per hour.
Methylene c1doride is used as the heat-transfer liquid ("brine") throughout the site's
Nation® Process Area. On October 31, 2013, a 3/8-inch copper tube fitting in the brine
system became detached, which resulted in the release of methylene chloride inside of the
Nation©Polymers Process manufacturing building.
This release from the brine system resulted in 1,181 pounds of methylene chloride being
unaccounted for and presumed to have been vented to the atmosphere through the NafionOO
Polymers Process stack(11)No. NEP-G) during a 1-hour period.
&I.du Pont de Nemours and Company

Mr. Steven F. Vozzo Page 2 of 2
NCDENR—Division of Air Quality , ,i ;
November I t,2013
The loss of 1,181 pounds of methylene chloride during a 1-hour period exceeds the Part I
Section 2,2(B)(1) limit of 24.851b/lu methylene chloride.
The cause of this deviation was due to a release of methylene chloride from a detached
copper tube fitting in the NafionO Process Area's brine system,
The NafionO Polymers Process is currently shutdown due to this incident. The brine
- system's copper tube fitting will have been reattached prior to the start-up of that Nation@
Polymers Process.
If you have any questions regarding this excess emission and permit deviation, or if you
need any additional information,please contact Michael Johnson at(910) 678-1155.
To comply with the requirement of Section 3(D) of the subject permit, the required
photocopy of this letter is enclosed.
By my signature below, I certify that I believe the information contained in this letter is
true, accurate,and complete,
Sincerely,
Ellis H. McGaughy
Plant Manager

OU PANT DuPont Chemicals&Fluoroproducts
Fayetteville Works Plant
22828 NC Hwy 87 West
RECEIVED Fayetteville,NC 28306-7332
NOV 13 2013
DENR-FAYETTEMLLE REGIONAL OFFICE
CERTIFIED MAIL ARTICLE NUMBER 7007 0710 0005 1455 9218
RETURN RECEIPT REQUESTED
November 11, 2013
Mr. Steven F. Vozzo
NCDENR—Division of Air Quality
Fayetteville Regional Office
225 Green Street—Suite 714
Fayetteville,NC 28301
SUBJECT: Title V Air Quality Permit Deviation and Excess Emissions
DuPont Company—Fayetteville Works
Air Quality Permit No. 03735T37
Facility ID: 0900009, Fayetteville, Bladen County
Dear Mr. Vozzo:
Pursuant to Part I Section 3(I.A)(2)(a) and Section 3(I.A.)(3)(a) of the subject Title V
permit, this letter is the required notification of excess emissions and a state-enforceable-
only permit deviation of an emissions limitation for methylene chloride specified in Part I
Section 2.2(B)(1) of the subject permit, which is the rule regulating North Carolina toxic
air pollutant emissions per 15A NCAC 2D .1100. That limitation sets a facility-wide
emission limit of 24.85 pounds of methylene chloride per hour.
Methylene chloride is used as the heat-transfer liquid ("brine") throughout the site's
Nafion® Process Area. On October 31, 2013, a 3/8-inch copper tube fitting in the brine
system became detached, which resulted in the release of methylene chloride inside of the
Nafion(&Polymers Process manufacturing building.
This release from the brine system resulted in 1,181 pounds of methylene chloride being
unaccounted for and presumed to have been vented to the atmosphere through the Nafion®
Polymers Process stack(ID No. NEP-G) during a 1-hour period.
E.I.du Pont de Nemours and Company

Mr. Steven F. Vozzo Page 2 of 2
NCDENR—Division of Air Quality
November 11, 2013
The loss of 1,181 pounds of methylene chloride during a 1-hour period exceeds the Part I
Section 2.2(B)(1) limit of 24.85 lb/hr methylene chloride.
The cause of this deviation was due to a release of methylene chloride from a detached
copper tube fitting in the Nafion®Process Area's brine system.
The Nafion® Polymers Process is currently shutdown due to this incident. The brine
_ system's copper tube fitting will have been reattached prior to the start-up of that Nafion®
Polymers Process.
If you have any questions regarding this excess emission and permit deviation, or if you
need any additional information, please contact Michael Johnson at [phone].
To comply with the requirement of Section 3(D) of the subject permit, the required
photocopy of this letter is enclosed.
By my signature below, I certify that I believe the information contained in this letter is
true, accurate, and complete.
Sincerely,
Ellis H. McGaughy
Plant Manager

Reeves, Gregory W
From: Reid, Mike
Sent: Thursday, October 31, 2013 4:02 PM
To: Reeves, Gregory W
Cc: Vozzo, Steven; Thomas, Mike; Cherry, Lori; Lewis, Steven
Subject: FW: NRC#1064549
Note update of the NRC report.
Michael Reid, 112(r) Program Coordinator Technical Services Section NC DENR, Division of Air
Quality
1641 Mail Service Center
. Raleigh, NC 27699-1641
Phone: [phone]
Fax: [phone]
www.ncair.org
mile.reid(@ncdenr.gov
*****************************************************************************************
Email correspondence to and from this address is subject to the North Carolina Public Records
Law and may be disclosed to third parties unless the content is exempt by statute or other
regulation.
*****************************************************************************************
-----Original Message-----
- From: Kenneth Rhame [mailto:Rhame.Kenneth(@epa.gov]
Sent: Thursday, October 31, 2013 3:55 PM
To: Reid, Mile; Lewis, Steven
Subject: Fw: NRC#1064549
From: HQS-PF-fldr-NRC(@uscg.mil <HOS-PF-fldr-NRC(dusca.mil>
Sent: Thursday, October 31, 2013 3:53:47 PM
To: Kenneth Rhame
Subject: NRC#1064549
NATIONAL RESPONSE CENTER 1-800-424-8802
******* NOTIFICATION UPDATE ALERT *******
Incident Report # 1064549
INITIAL INCIDENT DETAILS
Report Taken: 31-OCT-13 at 15:43
Incident Type: FIXED
Incident Cause: UNKNOWN
Location: City: FAYETTEVILLE County: BLADEN State: NC
--------------------------------------------------------------
**** UPDATED INFORMATION ****
Report Updated By: CIV TIMOTHY SMITH
Correction Released: 31-OCT-13 at 15:53
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Reeves, Gregory W
From: Reid, Mike
Sent: Thursday, October 31, 2013 4:00 PM
To: Reeves, Gregory W
Cc: 'Kenneth Rhame'; Lewis, Steven; Cherry, Lori; Colon, Teresa; Guan, Hong; Thomas, Mike;
Vozzo, Steven
Subject: FW: NRC#1064549
Just spoke w/ Mr. Johnson. Please disregard the "description of incident" section. The
release is confined to a tower not a town. Mr. Johnson was not able to offer me any more
clarification of the release at this time other then it appears to be contained. Mr. Johnson
further stated that he would send the NRC a clarification on the event description.
Mike R.
Michael Reid, 112(r) Program Coordinator Technical Services Section NC DENR, Division of Air
Quality
1641 Mail Service Center
Raleigh, NC 27699-1641
Phone: [phone]
Fax: [phone]
www.ncair.org
[e-mail]
*****************************************************************************************
Email correspondence to and from this address is subject to the North Carolina Public Records
Law and may be disclosed to third parties unless the content is exempt by statute or other
regulation.
*****************************************************************************************
-----Original Message-----
From: Kenneth Rhame [mailto:[e-mail]]
Sent: Thursday, October 31, 2013 3:51 PM
To: Reid, Mile; Lewis, Steven
Subject: Fw: NRC#1064549
From: [e-mail] <[e-mail]>
Sent: Thursday, October 31, 2013 3:49:06 PM
To: Kenneth Rhame
Subject: NRC#1064549
NATIONAL RESPONSE CENTER 1-800-424-8802
***GOVERNMENT USE ONLY***GOVERNMENT USE ONLY***
Information released to a third party shall comply with any
applicable federal and/or state Freedom of Information and Privacy Laws
Incident Report # 1064549
INCIDENT DESCRIPTION
*Report taken by: CIV DAVID DEDEAUX at 15:43 on 31-OCT-13
1

Incident Type: FIXED
Incident Cause: UNKNOWN
Affected Area:
Incident occurred on 31-OCT-13 at 15:35 local incident time.
Affected Medium: AIR ATMOSPHERE
REPORTING PARTY
Name: MICHAEL JOHNSON
Organization: DUPONT
Address: 22828 NC HWY 87W
FAYETTEVILLE, NC 28306
PRIMARY Phone: [phone] ALTERNATE Phone: [phone]
Type of Organization: PRIVATE ENTERPRISE
SUSPECTED RESPONSIBLE PARTY
_ Name: MICHAEL JOHNSON
Organization: DUPONT
Address: 22828 NC HWY 87W
FAYETTEVILLE, NC 28306
PRIMARY Phone: [phone] ALTERNATE Phone: [phone]
INCIDENT LOCATION
22828 NC HWY 87W County: BLADEN
City: FAYETTEVILLE State: NC Zip: 28306
RELEASED MATERIAL(S)
CHRIS Code: DCM Official Material Name: DICHLOROMETHANE
_ Also Known As:
Qty Released: 0 UNKNOWN AMOUNT
DESCRIPTION OF INCIDENT
CALLER STATED THAT THERE WAS A RELEASE OF DICHLOROMETHANE FROM AN
UNKNOWN SOURCE INSIDE A TOWN THAT IS BEING RESPONDED TO AT THIS
TIME.
SENSITIVE INFORMATION
INCIDENT DETAILS
Package: N/A
Building ID:
Type of Fixed Object: CHEMICAL FACILITY
Power Generating Facility: UNKNOWN
Generating Capacity:
Type of Fuel:
NPDES:
NPDES Compliance: UNKNOWN
IMPACT
Fire Involved: NO Fire Extinguished: UNKNOWN
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INJURIES: NO Hospitalized: Empl/Crew: Passenger:
FATALITIES: NO Empl/Crew: Passenger: Occupant:
EVACUATIONS:NO Who Evacuated: Radius/Area:
Damages: NO
Hours Direction of
Closure Type Description of Closure Closed Closure
N
Air:
N Major
Road: Artery:N
N
Waterway:
N
Track:
Environmental Impact: NO
Media Interest: UNKNOWN Community Impact due to Material:
REMEDIAL ACTIONS
INVESTIGATION UNDERWAY
Release Secured: YES
Release Rate:
Estimated Release Duration:
WEATHER
Weather: OVERCAST, °F
ADDITIONAL AGENCIES NOTIFIED
-- Federal:
State/Local:
State/Local On Scene:
State Agency Number:
NOTIFICATIONS BY NRC
DHS I&A STATE AND LOCAL PRGM OFFICE (RALEIGH, NC FUSION CENTER)
31-OCT-13 15:48 (202)5575179
DHS SOUTH CAROLINA FUSION CENTER (LE SENSITIVE ADVISORS & LIASON PROGRA
31-OCT-13 15:48 (866)4728477
DOT CRISIS MANAGEMENT CENTER (MAIN OFFICE)
31-OCT-13 15:48 (202)3661863
U.S. EPA IV (MAIN OFFICE)
(404)6504955
U.S. EPA IV (NC/SC INCIDENTS)
31-OCT-13 15:48 (404)6504955
NC DEPT OF EMERGENCY MGMT (MAIN OFFICE)
31-OCT-13 15:48 (800)8580368
NC OCCUPATIONAL ENVMTL EPIDEMIOLOGY (COMMAND CENTER)
31-OCT-13 15:48 (919)7075950
NC PUBLIC HEALTH PREPARE AND RESPNS (PHPR COMMAND CENTER)
31-OCT-13 15:48 (919)7150919
NATIONAL INFRASTRUCTURE COORD CTR (MAIN OFFICE)
31-OCT-13 15:48 (202)2829201
NOAA RPTS FOR NC (MAIN OFFICE)
31-OCT-13 15:48 (206)5264911
NATIONAL RESPONSE CENTER HQ (AUTOMATIC REPORTS)
3

31-OCT-13 15:48 (202)2671136
SEAHAWK IOC (INTER-AGENCY OPERATIONS CENTER)
31-OCT-13 15:48 (803)2060971
STATE OF NORTH CAROLINA DENR (MAIN OFFICE)
31-OCT-13 15:48 (919)8076300
USCG DISTRICT 5 (D5 DRAT)
31-OCT-13 15:48 (757)3986231
USCG DISTRICT 5 (INTEL CHIEF)
31-OCT-13 15:48 (757)3986655
ADDITIONAL INFORMATION
CALLER WILL NOTIFY THE STATE AND THE LEPC.
*** END INCIDENT REPORT #1064549 ***
Report any problems by calling 1-800-424-8802
PLEASE VISIT OUR WEB SITE AT http://www.nrc.uscg.mil
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