DEQ-CFW_00076817

. ,o
AGA
NCDENR
North Carolina Department of Environment and Natural Resources
Michael F. Easley, Governor December 27, 2001 William G. Ross Jr., Secretary
Gregory J. Thorpe, Ph.D.
Mr. Michael. Johnson, Environmental Manager Acting Director
E. I. Dupont de Nemours & Company, Inc. Division of Water Quality
22828 NC Hwy. 87 West
Fayetteville, NC 28306
SUBJECT: Compliance Evaluation Inspection
E. I. Dupont de Nemours & Company, Inc.
Wastewater Treatment Plant
NPDES Permit No. NC0003573
Bladen County
Dear Mr. Johnson:
Enclosed is a copy of the Compliance Evaluation Inspection conducted December 13, 2001.
As part of the inspection a tour of the Wastewater Treatment Plant was conducted. All observations
and recommendations are in Part D. Summary of Findings/Comments of this inspection report. The
cooperation of Mr. Robert Geddie, Grade IV ORC was greatly appreciated. During the inspection
a copy of the NPDES Compliance Reminders were reviewed and left with facility staff. As a
reminder preservation of the Waters of the State can only be acquired through consistent NPDES
permit compliance.
Please review the attached report. If you or your staff have any questions do not hesitate
to contact me at 910-486-1541.
Sincerely,
Belinda S. Henson
Environmental Chemist
/bsh
Enclosures
cc: Mr. Robert Geddie, ORC, E. I. Dupont
Fayetteville Regional Office
225 Green Street — Suite 714, Fayetteville, North Carolina 28301-5043
Phone: [phone] FAX: [phone] \ Internet: www.enr.state.nc.us/ENR
An Equal Opportunity 1 Affirmative Action Employer — 50% Recycled 110% Post Consumer Paper
DEQ-CFW 00076817

J iJ , • U33
I,111Hnm uz i Nee in AIQ
0 t NPDES COMPLIANCE INSPECTION REPORT
North Carolina Division of Water Quality
5 Iwo' Y
Fa etteville Regional Office
Section A. National Data System Coding
Transaction Code: N NPDES NO. NC0003573 Date: 011213
Inspector: S Facility Type:2
Facility Evaluation Rating: 4 BI: N QA: N
Section B: Facility Data
Name and Location of Facility Inspected:
E. I. Dupont de Nemours WWTP
Entry Time/Date: 9:50am/011213
Exit Time/Date: 1:OOpm/011213
Name(s), Title(s) of On -Site Representative(s):
Robert Geddie - (Certified Grade IV) - "ORC"
Phone Number(s): [phone]
Name, Title and Address of Responsible Official:
Mr. Michael Johnson, Environmental Manager
22828 NC Hwy. 87 West
Fayetteville, NC 28306
Section C: Areas Evaluated During Inspection
Inspection Type: C
Reserved:
Reserved:
Permit Effective Date: 001101
Permit Expiration Date: 011031
Contacted: no
S = Satisfactory, M = Marginal, U = Unsatisfactory, N = Not Evaluated, N/A = Not Applicable)
i
DEQ-CFW 00076818

Johnson
Page 3
December 27, 2001
1. The wastewater facility furnishes treatment to the following industries: PMDF, Dymetrol, Nafion, and
Butacite. Mineral by products from the water treatment system is also discharged into the W WTP. All
the industries are owned by Dupont with the exception of Dymetrol.
2. Approximately 20,000 gallons per day of domestic wastewater is discharge into the treatment works.
All wastewater enters the head of the plant by gravity. Four (4) influent pumps are onsite to bring the
flow into the plant.
3. Ammonia and Phosphoric acid are added each day as a food source to enable the bacteria to live and
reproduce.
4. The flow travels from the Headworks to the aerated pre -digester tank. The tank appeared to be
operational. The flow normally travels to the EQ basin first but the facility is troubleshooting high pHs
and are not using the EQ basin at this time.
5. The waste stream flows from the pre -digester tank to the aeration tank forjurther treatment. The
diffused air system in the aeration tank appeared to be operating adequately. A Biomixer which mixes
and adds air in an area where the flow enters the tank was not operational. It is presently under repair.
The most recent Mixed Liquor Suspended Solids (MISS) result for December 13, 2001 was 3683 mg/L.
The MLSS goes into a preaeration tank where excess oxygen is taken out. This part of the treatment
assists in keeping solids from floating on the surface of the clarifiers.
6. Clarifier #1 and Clarifier #2 appeared to be operational. An antifoam agent is added to the clarifiers
to eliminate foaming problems. Polymer is also added when needed to assist with solids settling.
Clarifiers are taken out of service monthly for maintenance and repair.
7. The effluent appeared to be free of solids. The effluent outfall is easily accessible from the area near
the William O. Huske Lock and Dam # 1.
8. The effluent composite sampler temperature appeared to be adequate at 4 degrees C. The acceptable
temperature range samples during storage and for stored sample extracts, is 1.0 - 4.4 degrees C. The
effluent sampler tubing for pipes 001(process wastewater) and 002 (cooling water) combined appeared
to have some solids or algae buildup in it. Increase in frequency of changing the tubing could enhance
the quality of the composite sample.
9. The effluent flow meter was calibrated May 10, 2001 by "Water and Waste Technical Services". It is
advisable that the flow meter calibration document contain the % error before and after calibration in the
future by the technician.
DEQ-CFW 00076819

Johnson
Page 4
December 27, 2001
10. Solids are wasted to the DAF unit and then to the sludge thickener and finally to the sludge filter press.
The DAF unit was not operating at the time of the inspection but repairs were going to be implemented
immediately as per staff. Polymer is added to the biosolids before they enter the press to assist with
dewatering. Solids content leaving the press are between 11 and 12 %. From the press, solids are dried
and lime is added and treatment of biosolids are complete. Biosolids leaving the oven are between 40
and 60% solids. I
11. Sludge disposal is by "Waste Industries" which transports the dried biosolids to their landfill in
Roseboro (Sampson County).
12. All maintenance records are on computer and documentation is incorporated by the Powerhouse
(Utilities) division of this facility which is located onsite.
13. As Built engineering drawings and O & M manuals are located at the Powerhouse as per Mr. Geddie.
14. The facility's present permit expired October 31, 2001. They have applied for renewal and will continue
to operate under the present permit until a new one is submitted to the facility.
15. "Simalab" analyzes all NPDES permit required parameters with the exception of the pH and
Temperature which are done by facility staff.
16. Laboratory records were reviewed for the months February and April 2001 and compared to Discharge
Monitoring Reports. All records reviewed appeared to be accurate.
17. A compliance evaluation analysis report for the period September 2000 through August 2001 revealed
a monthly BOD violation in February 2001. A Notice of Violation (NOV) was submitted to the facility
for the BOD violation.
DEQ-CFW 00076820

Name and Signature of Inspector
Belinda
,S,.�Henson
Name and Signature of Reviewer
Paul E. Rawls
Agency/Office/Telephone Date
DENR/Fayetteville/[phone] )1 2_7-U 1
Agency/Office/Telephone Date
DENR/Fayetteville/[phone]
1'
Regulatory Office Use Only
Action Taken Compliance Status
Noncompliance
Compliance
0
Date
DEQ-CFW 00076821

S31Li WHIN ,?
AJ.INnIn u-novio k1t 410
o1
_ 1 r 1Fesc
��� i 1! 11 4- I1 •
The WWTP consists of equalization. neutralization- aerated =-digester tank, a nutrient feed
systLM an aerationdual clarifiers.• • .. filter for
sludge thickening, a sludge filter press and steam heated sludge dEyers (001); boiler blowdown
from Dupont oil -fired boilers, boiler blowdown and cooling tower blowdown from BCH Energy
PEQject. once throughcooling watcL tmated wastewater effluentfrom 0 1001.• •
biodegradable process wastewater from Outfall (006), and filter backwash discharge (002).
FACILITY SITE REVIEW
esi No N/A 1. Treatment units properly operated and maintained.
Yes
No
2.
Standby power or other equivalent provision provided.
Yes
No
N/A.
3.
Adequate alarm system for power or equipment failure available.
4. Sludge disposal procedures appropriate:
3 No N/A a. Disposal of sludge according to regulations
No N/A b. State approval for sludge disposal received.
X§s',No N/A 5. Sufficient sludge disposed of to maintain treatment process equilibrium.
es No N/A 6. The ORC and Backup Operator are officially designated with
NCDENR/DWQ Training and Certification Unit.
es - No N/A 7. Adequate spare parts and supplies inventory maintained.
Yes No N/A 8. Plant has general safety structures such as rails around or covers over
tanks, pits, or wells.
O. es `No N/A 9. Plant is generally clean, free from open trash areas.
10.
Screening:
Yes
No
(LTtA
a. Manual
Yes
No
N/A
b. Mechanical
Yes
No
,
N/A
c. Buildup of debris
Yes
No
N/A
d. Screenings properly disposed of.
11. Grit Removal:
Yes No a. Excessive organic content in the grit chamber
Yes No N/A b. Excessive odors
Yes No N/A c. Grit properly disposed of.
DEQ-CFW 00076822

Page 2
12.
Primary clarifier:
Yes
No
(n)
a.
Excessive gas bubbles
Yes
No
N/A
b.
Black and odorous wastewater
Yes
No
N/A
c.
Poor suspended solids removed
Yes
No
N/A
d.
Excessive buildup of solids in center well of circular clarifier
Yes
No
NIA
e.
Weirs level
Yes
No
N/A
f.
Weir blockage
Yes
No
N/A
g.
Evidence of short circuiting
Yes
No
N/A
h.
Lack of adequate scum removal
Yes
No
N/A
i.
Excessive floating sludge
Yes
No
N/A
j.
Broken sludge scraper.
13. Trickling Filter:
Yes
No
a.
Trickling filter ponding(indicating clogged media)
Yes
No
NIA
b.
Leak at center column of trickling filter's distribution arms
Yes
No
N/A
c.
Uneven distribution of flow on trickling filter surface
Yes
No
N/A
d.
Uneven or discolored growth
Yes
No
N/A
e.
Excessive sloughing of growth
Yes
No
NIA
f.
Odor
Yes
No
NIA
g.
Clogging of trickling filter's distribution arm orifices
Yes
No
N/A
h.
Filter flies, worms, or snails.
14. Activated Sludge Basins/Oxidation Ditches:
Yes Qb N/A
a.
Dead spots
Yes No (g�
b.
Failure of surface aerators
Yes <0 N/A
c.
Air rising in clumps
Yes N/A
d.
Dark foam or bad color
Yes T N/A
e.
Thick billows of white, sudsy foam
Yes N/A
f.
Air rising unevenly
Yes RC �' N/A
g.
Excessive air leaks in compressed air piping.
15.
Stabilizatiorl Ponds/Lagoons:
Yes No 01
a.
Excessive weeds including duckweed in stabilization ponds
Yes No N/A
b.
Dead fish or aquatic organisms
Yes No. NIA
c.
Buildup of solids around influent pipe
Yes No N/A
d.
Excessive scum on surface.
DEQ-CFW 00076823

TIMM
aq* 0 A►r.
Yes N/A
Yes N/A
Yes N/A
Yes N/A
Yes N/A
(Y-a No N/A
Yes (Q N/A
Yes d�3 NIA
Yes QP N/A
Secondary Clarifier:
a. Excessive gas bubbles on surface
b. Level overflow weirs
c. Weir blockage
d. Evidence of short circuiting
e. Excessive buildup of solids in center well of circular clarifier
f. Pin floc in overflow
g. Effective scum rake
h. Floating sludge on surface
i. Excessive high sludge blanket
j. Clogged sludge withdrawal ports on secondary clarifier.
17.
Filtration:
Yes
No
�
a.
Filter surface clogging
Yes
No
N/A
b.
Short filter run
Yes
No
N/A
c.
Gravel displacement of filter media
Yes
No
N/A
d.
Loss of filter media during backwashing
Yes
No
N/A
e.
Recycled filter backwash water in excess of 5 percent
Yes
No
N/A
f.
Formation of mudballs in filter media.
18. Chlorination Unit:
Yes
No
�O
a.
Sludge buildup in contact chamber
Yes
No
N/A
b.
Gas bubbles
Yes
No
N/A
c.
Floating scum and/or solids
Yes
No
N/A
d.
Adequate ventilation of chlorine feeding room and storage area
Yes
No
N/A
e.
NIOSH-approved 30 minute air pack
Yes
No
N/A
f.
All standing chlorine cylinders chained in place
Yes
No
N/A
g.
All personnel trained in the use of chlorine
Yes
No
N/A
h.
Proper chlorine feed, storage, and reserve supply.
Yes No (�?p 19. Ultraviolet radiation disinfection present and in use.
20. Dechlorination:
Yes No fFN a. Proper storage of sulfur dioxide cylinders
Yes No N/A b. Adequate ventilation of sulfur dioxide feeding room
Yes No N/A c. Automatic sulfur dioxide feed or feedback control operating
properly.
21. Aerobic Digester:
Yes
No
N/A
a. Excessive foaming in tank
Yes
No
N/A
b. Noxious odor
Yes
No
N/A
c. Mechanical aeration failure
Yes
No
N/A
d. Clogging of diffusers.
DEQ-CFW 00076824

Page 4
Yes No C fi�11
Yes No N/A
Yes
No RN
Yes
No
Yes
No
Yes
No
Yes
No (&R,
es
No N/A
Yes
No
22. Anaerobic Digester:
a. Floating cover tilting
b. Gas burner operative
23. Sludge Drying and/or disposal:
a. Poor sludge distribution on drying beds
b. Vegetation in drying beds
c. Dry sludge remaining in drying beds
d. Dry sludge stored on site
e. Filtrate from sludge drying beds returned to front of plant
f. Sludge disposal through county landfill. Sca-mfson Coun-l+�
g. Sludge land applied.
24. Filter Press:
Yes OP N/A a. High level of solids in filtrate from filter presses or vacuum filters
Yes �W N/A b. Thin filter cake caused by poor dewatering
Yes 96 N/A c. Sludge buildup on belts and/or rollers of filter press
Yes Qb N/A d. Excessive moisture in belt filter press sludge cake.
25. Polishing Ponds or Tanks:
Yes No (25) a. Objectionable odor, excessive foam, floating solids, or oil sheens on
water surface
Yes No N/A b. Solids or scum accumulations in tank or at side of pond
Yes No N/A c. Evidence of bypassed polishing ponds or tanks because of low
capacity.
26. Plant Effluent:
Yes (93 N/A a. Excessive suspended solids, turbidity, foam, grease, scum, color, and
other macroscopic particulate matter present
Yes T& N/A b. Potential toxicity (dead fish, dead plant at discharge)
(S No N/A c. Outfall discharge line easily accessible.
27. Flow Measurement: '
C je No
N/A
a.
Proper placement of flow measurement device
Yes No
N/A
b.
Flow meter calibrated
Yes Q�Z
N/A
c.
Buildup of solids in flume or weir
Yes (&'
N/A
' d.
Broken or cracked flume or weir
Yes No
(0
e.
Clogged or broken stilling wells
Yes (95�
N/A"
f
Weir plate edge corroded or damaged
Yell ,No
N/A
g..
Flow measurement error less than 10%.
DEQ-CFW 00076825

S3113 WS1N33
Page) JLljWr%r, Un IWAA Jn Ala
700� 081 Wgialiaosite
e ing and analysis completed on parameters specified by permit
sample temperatures maintained at 4 degrees Celsius or
less (but above freezing) during sampling
No N/A c. Contract laboratory used for sample analysis
No N/A d. Effluent composite samples obtained are flow proportional.
I
RECORDKEEPING AND REPORTING
es No N/A 1. Records and reports maintained as required by permit.
es) No N/A 2. All required information available, complete, and current.
Yes No N/A 3. Records maintained for 3 years and all sludge records maintained for 5
years.
(FesJ No N/A 4. Analytical results consistent with data reported on DMRs.
5. Sampling and analyses data adequate and include:
Yes
No
N/A
a.
Dates, times, and location of sampling
Yes
No
N/A
b.
Name of individual performing sampling
Yes
No
N/A
c.
Results of analyses and calibration
Yes
No
N/A
d.
Dates of analyses
Yes
No
N/A
e.
Name of person performing analyses.
6. Monitoring records adequate and include:
Yes No N/A a. Monitoring charts kept for 3 years
Yes No N/A b. Flowmeter calibration records kept for 3 years.
(YZ�� No N/A 7. The pH meter is calibrated daily with two buffers and checked with a
. third buffer and properly documented.
(Ye .) No N/A S. Expiration dates of pH buffers adequate.
es, No N/A �9. All thermometers used in NPDES permit reporting is calibrated
annually with an NIST certified thermometer or a traceable
thermometer annually and documented.
Ye7No N/A 10. The following NPDES permit required parameters are analyzed on site:
pH, Temperature, Dissolved Oxygen and Chlorine Residual.
DEQ-CFW 00076826

-ro V
Page 6
Yes No 11. The NPDES permit required parameter Total Chlorine Residual is
analyzed by approved method.
Yes No C 12. BOD incubator temperature maintained at 20 +/- 1 Degrees Celsius
and the temperature maintained in a log for every day of operation.
Yes No N%' 13. Fecal coiiform incubator maintained at 44.5 +/- 0.2 Degree Celsius and
the temperature maintained in a log for every day of operation.
14. Plant records adequate and include:
Yes
No
N/A
a. O & M Manual
Yes
No
N/A
b. "As -built" engineering drawings
Yes
No
N/A
c. Schedules and dates of equipment maintenance repairs
Yes
No
N/A
d. Equipment data cards.
Yes No N/ 15. Permittee is meeting compliance schedule.
No N/A 16. DMRs complete and include all NPDES permit required parameters.
Yes No 17. The facility has a permitted flow greater than 5 MGD and is required
to operate seven days per week 24 hours a day.
CYe
V No N/A 18. ORC visitation logs available and current.
rYew No N/A 19. ORC certified at a level equal to or greater than the classification of.
the wastewater facility.
(rep No N/A 20. Backup Operator certified at one level less than the classification of
the wastewater facility or greater. °
Yes No N/A 21. Current copy of the complete NPDES permit on site.
Yes No . Nits''' 2r1' Facility description verified as contained in NPDES permit.
Yes N/A 23. 14ility analyzes process control parameters for example: MLSS,
t*MCRT, Settleable Solids and others that are applicable.
Yes No 24. .Industrial Waste Surveys (IWS) sent to all possible Significant
Industrial Users (SIUs) within the last five years (especially new
industries).
Revised 7/16/01
by Belinda Henson
DEQ-CFW 00076827

;,e
14
t!!! b
DI'V ur ##J41 cn WUAUTY
Mom- FILES
DEQ-CFW 00076828