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Home My WebLink AboutNC0003760_Compliance Evaluation Inspection_20210107L� sa SfA7� � ROY COOPER Governor � - 1vIICHAEL S. REGAN .�µ. Secr&vey S. DANIEL SMITH NORTH CAROLINA Director Environmental Quality January 07, 2021 George Xenakis Dupont Industrial Biosciences USA LLC 4693 HWY 11N Grifton, NC 28530 SUBJECT: Compliance Inspection Report E.I. DuPont Kinston Plant NPDES WW Permit No. NC0003760 Lenoir County Dear Mr. Xenakis: The North Carolina Division of Water Resources conducted an inspection of the E.I. DuPont Kinston Plant on 1/05/2021. This inspection was conducted to verify that the facility is operating in compliance with the conditions and limitations specified in NPDES WW Permit No. NC0003760. The findings and comments noted during this inspection are provided in the enclosed copy of the inspection report entitled "Compliance Inspection Report". If you should have any questions, please do not hesitate to contact me with the Water Quality Regional Operations Section in the Washington Regional Office at 252-948-3843 or via email at robert.e.bullock@ncdenr.gov. Sincerely, Robbie Bullock, Environmental Specialist II Water Quality Regional Operations Section Washington Regional Office Division of Water Resources, NCDEQ ATTACHMENTS Cc: Laserfiche igAwNorth Carol na Department of Enuironrnental Quality I DvAsion of Water Resources Washington Region al Office 1943 Washington Sq awe Ma11 I Washington, North Cam! ins 27339 2524W-6431 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 IN 1 2 u 3 I NC0003760 I11 121 21/01/05 I17 18LC I 19 Ls_] 201 r,l 211111 I I I I I I II I I I I I I I I I I I I I I I I I I I I I I I II I I I I I r6 Inspection Work Days Facility Self -Monitoring Evaluation Rating B1 QA ---------------------- Reserved ------------------- 67 I 72 I n,J I I I 71 I 74 79 I I I I I I I80 701� I 711 L LJ L 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) 09:30AM 21/01/05 17/04/01 E.I. DuPont Kinston Plant 4693 Hwy 11 N Exit Time/Date Permit Expiration Date Grifton NC 28530 12:OOPM 21/01/05 22/03/31 Name(s) of Onsite Representative(s)/Titles(s)/Phone and Fax Number(s) Other Facility Data Jeffrey Alan White/ORC/252-522-6443/ Name, Address of Responsible Official/Title/Phone and Fax Number Contacted James Proctor,PO Box 937 Stoneville NC 27048//336-573-4201/3365734218 No Section C: Areas Evaluated During Inspection (Check only those areas evaluated) Permit 0 Flow Measurement Operations & Maintenar Records/Reports Self -Monitoring Progran 0 Sludge Handling Dispo: Facility Site Review Effluent/Receiving Wate 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 Robert E Bullock DWR/Division of Water Qua Iity/252-948-3924/ 1 /7/2021 Signature of Management Q A Reviewer Agency/Office/Phone and Fax Numbers Date EPA Form 3560-3 (Rev 9-94) Previous editions are obsolete. Page# NPDES yr/mo/day Inspection Type NC0003760 I11 12I 21/01/05 117 18 i c i (Cont.) Section D: Summary of Finding/Comments (Attach additional sheets of narrative and checklists as necessary) The review period for this inspection was September 2018 through October 2020. The current permit is effective until March 31, 2022. The facility was reminded that a renewal application must be submitted 180 days prior to the permit expiration. On high flows the v notch weir located at outfall 002 is not capable of measuring the entire flow. A flow measurement device needs to be installed at Outfall 002 that can measure the entire flow during high flow events The facility appeared to be COMPLIANT with NPDES permit NC0003760 Page# Permit: NC0003760 Owner - Facility: E.I. DuPont Kinston Plant Inspection Date: 01/05/2021 Inspection Type: Compliance Evaluation Operations & Maintenance Yes No NA NE Is the plant generally clean with acceptable housekeeping? 0 ❑ ❑ ❑ Does the facility analyze process control parameters, for ex: MLSS, MCRT, Settleable ❑ ❑ ❑ Solids, pH, DO, Sludge Judge, and other that are applicable? Comment: Record Keeping Yes No NA NE Are records kept and maintained as required by the permit? 0 ❑ ❑ ❑ Is all required information readily available, complete and current? 0 ❑ ❑ ❑ Are all records maintained for 3 years (lab. reg. required 5 years)? 0 ❑ ❑ ❑ Are analytical results consistent with data reported on DMRs? 0 ❑ ❑ ❑ Is the chain -of -custody complete? 0 ❑ ❑ ❑ 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? 0 ❑ ❑ ❑ Has the facility submitted its annual compliance report to users and DWQ? ❑ ❑ 0 ❑ (If the facility is = or > 5 MGD permitted flow) Do they operate 24/7 with a certified operatc ❑ ❑ ❑ on each shift? Is the ORC visitation log available and current? ❑ ❑ ❑ 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 ❑ ❑ ❑ Facility has copy of previous year's Annual Report on file for review? ❑ ❑ 0 ❑ Comment: Jeff White is the ORC with Randall Harrell as the Backup ORC. The October 2020 eDMR was spot checked for accuracy with no discrepancies found. Permit Yes No NA NE (If the present permit expires in 6 months or less). Has the permittee submitted a new ❑ ❑ 0 ❑ application? Is the facility as described in the permit? 0 ❑ ❑ ❑ # Are there any special conditions for the permit? 0 ❑ ❑ ❑ Page# 3 Permit: NC0003760 Owner - Facility: E.I. DuPont Kinston Plant Inspection Date: 01/05/2021 Inspection Type: Compliance Evaluation Permit Yes No NA NE Is access to the plant site restricted to the general public? 0 ❑ ❑ ❑ Is the inspector granted access to all areas for inspection? E ❑ ❑ ❑ Comment: The current permit is effective until March 31, 2022. The facility was reminded that a renewa application must be submitted 180 days prior to the permit expiration. Bar Screens Type of bar screen a.Manual b.Mechanical Are the bars adequately screening debris? Is the screen free of excessive debris? Is disposal of screening in compliance? Is the unit in good condition? Yes No NA NE ■ ❑ ❑ ❑ ❑ ❑ ■ ❑ ❑ ❑ ■ ❑ ■ ❑ ❑ ❑ Comment: Sanitary sewer goes throuqh a "Muffin Monster" solids grinder before it is sent to the WWTP 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? Yes No NA NE ❑ ■ ❑ ❑ • ❑ ❑ ❑ • ❑ ❑ ❑ • ❑ ❑ ❑ • ❑ ❑ ❑ ❑ ❑ ■ ❑ ❑ ❑ ■ ❑ ■ ❑ ❑ ❑ Comment: Two equalization basins are located at the WWTP. On the day of inspection a sump pump was pumping wastewater from the equalization basin to the WWTP for treatment. There is an overflow pipe located in the equalization basin that discharges into the aeration basin. In the event of a high level in the equalization basin the wastewater will flow into the WWTP. Aeration Basins Mode of operation Type of aeration system Is the basin free of dead spots? Yes No NA NE Surface ❑ ❑ ❑ Page# 4 Permit: NC0003760 Owner - Facility: Inspection Date: 01/05/2021 Inspection Type: E.I. DuPont Kinston Plant Compliance Evaluation Aeration Basins Yes No NA NE 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? 0 ❑ ❑ ❑ Is the DO level acceptable? 0 ❑ ❑ ❑ Is the DO level acceptable?(1.0 to 3.0 mg/1) 0 ❑ ❑ ❑ Comment: Nutrient Removal Yes No NA NE # Is total nitrogen removal required? 0 ❑ ❑ ❑ # Is total phosphorous removal required? 0 ❑ ❑ ❑ Type Biological # Is chemical feed required to sustain process? ❑ 0 ❑ ❑ Is nutrient removal process operating properly? 0 ❑ ❑ ❑ Comment: Nutrient Removal is biological Secondary Clarifier Yes No NA NE Is the clarifier free of black and odorous wastewater? 0 ❑ ❑ ❑ Is the site free of excessive buildup of solids in center well of circular clarifier? 0 ❑ ❑ ❑ Are weirs level? 0 ❑ ❑ ❑ Is the site free of weir blockage? 0 ❑ ❑ ❑ Is the site free of evidence of short-circuiting? 0 ❑ ❑ ❑ Is scum removal adequate? ❑ ❑ 0 ❑ Is the site free of excessive floating sludge? 0 ❑ ❑ ❑ Is the drive unit operational? 0 ❑ ❑ ❑ Is the return rate acceptable (low turbulence)? 0 ❑ ❑ ❑ Is the overflow clear of excessive solids/pin floc? 0 ❑ ❑ ❑ Is the sludge blanket level acceptable? (Approximately'/ of the sidewall depth) ❑ ❑ ❑ Comment: Pumps-RAS-WAS Yes No NA NE Are pumps in place? 0 ❑ ❑ ❑ Are pumps operational? 0 ❑ ❑ ❑ Page# 5 Permit: NC0003760 Owner - Facility: E.I. DuPont Kinston Plant Inspection Date: 01/05/2021 Inspection Type: Compliance Evaluation Pumps-RAS-WAS Yes No NA NE Are there adequate spare parts and supplies on site? 0 ❑ ❑ ❑ Comment: Drying Beds Yes No NA NE Is there adequate drying bed space? 0 ❑ ❑ ❑ Is the sludge distribution on drying beds appropriate? ❑ ❑ 0 ❑ Are the drying beds free of vegetation? 0 ❑ ❑ ❑ # Is the site free of dry sludge remaining in beds? 0 ❑ ❑ ❑ Is the site free of stockpiled sludge? 0 ❑ ❑ ❑ Is the filtrate from sludge drying beds returned to the front of the plant? 0 ❑ ❑ ❑ # Is the sludge disposed of through county landfill? 0 ❑ ❑ ❑ # Is the sludge land applied? ❑ ❑ 0 ❑ (Vacuum filters) Is polymer mixing adequate? ❑ ❑ 0 ❑ Comment: Sludge is disposed of in the Bertie County Landfill Flow Measurement - Effluent Yes No NA NE # Is flow meter used for reporting? 0 ❑ ❑ ❑ Is flow meter calibrated annually? 0 ❑ ❑ ❑ Is the flow meter operational? 0 ❑ ❑ ❑ (If units are separated) Does the chart recorder match the flow meter? ❑ ❑ 0 ❑ Comment: The effluent flow meter for Outfall 001 was calibrated on April 3, 2020 by Hach. On high flows the v notch weir located at outfall 002 is not capable of measuring the entire flow. A flow measurement device needs to be installed at 002 that can measure the entire flow during high flow events Effluent Sampling Is composite sampling flow proportional? Is sample collected below all treatment units? Is proper volume collected? Is the tubing clean? # Is proper temperature set for sample storage (kept at less than or equal to 6.0 degrees Celsius)? Is the facility sampling performed as required by the permit (frequency, sampling type representative)? Yes No NA NE ■ ❑ ❑ ❑ ■ ❑ ❑ ❑ ■ ❑ ❑ ❑ ❑ ❑ ❑ ■ ❑ ❑ ❑ ■ ❑ ❑ ❑ Page# 6 Permit: NC0003760 Owner - Facility: E.I. DuPont Kinston Plant Inspection Date: 01/05/2021 Inspection Type: Compliance Evaluation Effluent Sampling Yes No NA NE Comment: Outfall 001 sampler is flow proportional and the sampler temperature was 4 degrees on the day of inspection. Outfall 002 sampler is on constant time and constant volume. Outfall 003 sampler is on constant time and constant volume. The sampler temperature was 6 degrees on the day of inspection. Outfalls 004, 005 and 006 are Stormwater outfalls. Division of Energy, Mineral and Land Resources has oversight of these outfalls. Effluent Pipe Yes No NA NE Is right of way to the outfall properly maintained? 0 ❑ ❑ ❑ Are the receiving water free of foam other than trace amounts and other debris? 0 ❑ ❑ ❑ If effluent (diffuser pipes are required) are they operating properly? ❑ ❑ 0 ❑ Comment: On the day of inspection outfall 001 was flooded due to high river levels and outfall 002 was not easily assessable due to the recent rains. Outfalls 003, 004, 005 and 006 were observed during the inspection Upstream / Downstream Sampling Yes No NA NE Is the facility sampling performed as required by the permit (frequency, sampling type, an( 0 ❑ ❑ ❑ sampling location)? Comment: DuPont is a member of the Neuse River Basin Association and stream sampling is waived as long as the facility maintains membership in the Lower Neuse Basin Association Page# 7