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Home My WebLink AboutNC0003719_Inspection_20040519oFW A rFRQG 1,DWO 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 May 19, 2004 Stanley Carter, Service Complex Site Manager DAK Resins LLC PO Box 1690 Fayetteville NC 28312 SUBJECT: May 6, 2004 Compliance Evaluation Inspection DAK Resins LLC DAK Resins LLC - Fayetteville Permit No: NC0003719 Cumberland County Dear Mr. Carter: Enclosed please find a copy of the Compliance Evaluation Inspection form from the inspection conducted on May 6, 2004. The Compliance Evaluation Inspection was conducted by Belinda S. Henson and Mike Lawyer of the Fayetteville Regional Office. The cooperation of Mr. Donald Allbright, ORC was greatly appreciated. The facility was found to be in Compliance with permit NC0003719. 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. Sincerely, Belinda &Henson Environmental Chemist cc: Donald Ray Allbright, ORC Central Files Fayetteville Files NCDENR is NCDENR Division of Water Quality Customer Service 1 877 623-7748 225 Green Street -Suite 714 . Fayetteville, NC 28301-50431 (910)486-1541 Telephone (910)486-0707 Fax United States Environmental Protection Agency EPA ^ Washington, D.C. 20460 Water Compliance Inspection Report Form Approved. OMB No. 2040-0057 Approval expires 8-31-98 Section A: National Data System Coding (i.e., PCS) Transaction Code NPDES yr/mo/day Inspection 1 1 N 1 2 U 31 NC0003719 111 121 04/05/06 117 Type Inspector Fac Type 18 LI 19 I S I 20 L_I Remarks 21IIIIIIIIIIII11111111111111IIIIIIIIIIIIIillllll166 Inspection Work Days Facility Self -Monitoring Evaluation Rating B1 QA --- Reserved 671 1 69 701 J 71 1 NJ 721 j 11 174 751 1 1 1 1 1 1 1 80 Section B: Facility Data Name and Location of Facility Inspected (For Industrial Users discharging to POTW, also include POTW name and NPDES permit Number) DAK Resins LLC - Fayetteville 3468 Cedar Creek Road Fayetteville NC 28302 Entry Time/Date 09:30 AM 04/05/06 Permit Effective Date 03/04/01 Exit Time/Date 12:30 PM 04/05/06 Permit Expiration Date 06/10/31 Name(s) of Onsite Representative(s)/Titles(s)/Phone and Fax Number(s) Donald Ray Allbright/ORC/910-433-4259/ /// Other Facility Data Name, Address of Responsible Official/Title/Phone and Fax Number Craig Leite,PO Box 1690 Fayetteville NC 28312/Site Contacted• No Manager/910-433-8254/ Section C: Areas Evaluated During Inspection (Check only those areas evaluated) Permit ■ Flow Measurement 1 Operations & Maintenance • Records/Reports Effluent/Receiving Waters Self -Monitoring Program Sludge Handling Disposal 1 Facility Site Review • 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 Belinda S Henson `•Z;-;1,0 G7�1.. . y '%10tri"C) FRO WQ//91048615411726/910-486-0707 8_ IS -0 /^L Signature of Manag ent vie r Agency/Office/Phone and Fax Numbers Date Paul E Rawls 91048615411726/910-486-0707 EPA Form 3560-3 (Rev 9-94) Previous editions are obsolete. 31 NPDES yr/mo/day NC0003719 111 12 04/05/06 117 Inspection Type 18 ,U 1 Section D: Summary of Finding/Comments (Attach additional sheets of narrative and checklists as necessary) The facility accepts wastewater from the following industries located on the complex site: Dupont and DAK. Dupont manufactures film and DAK manufactures plastic chips for drink bottles and food products. The influent flow is generated from these two facilities. Aeration Basin #1 is presently used as a digester. It is fed into the plant slowly until a pumping system can be implemented to pump directly into the digester. Permit:. NC0003719 Owner - Facility: DAK Resins LLC - DAK Resins LLC - Fayetteville Inspection Date: 05/06/04 Inspection Type: Compliance Evaluation Permit (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: Operations & Maintenance Does the plant have general safety structures in place such as rails around or covers over tanks, pits, or wells? Is the plant generally clean with acceptable housekeeping? Comment: Pump Station - influent Is the pump wet well free of bypass lines or structures? Is the general housekeeping acceptable? 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? Is audible and visual alarm available and operational? Comment: Fnuali7ation Basins Is aeration adequate? Is the basin free of bypass lines or structures to the natural environment? Is the general housekeeping acceptable? 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 NF O ❑ • ❑ • ❑ ❑ ❑ • ❑ ❑ ❑ ■ ❑❑❑' • ❑ ❑ ❑ Yes No NA NF • ❑ ❑ ❑ • ❑ ❑ ❑ Yes No NA NF ❑ ❑ 1 ❑ ❑ ❑•❑ ❑ ❑•❑ ❑ ❑ • ❑ ❑ ❑• ❑. O ❑ ■ ❑ ❑ O ■ O ❑ ❑•❑ Yes No NA NF ❑ O ■ ❑ ❑ ❑ ❑• ■ ❑ ❑ 0 .0 ❑ ❑•- ❑ ❑•❑ ❑ ❑ ■ ❑ ❑ ❑ ■ ❑ ❑ ❑ ■ ❑ • ❑ ❑ ❑ Comment:Wastewater is pumped into the two (2) EQ basins parallel and then they flow by gravity into the headworks of the WWTP. Secondary Clarifier Yes No NA NF 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? Is scum removal adequate? Is the site free of excessive floating sludge? Is the drive unit operational? Is the sludge blanket level acceptable? Is the return rate acceptable (low turbulence)? Is the overflow clear of excessive solids/pin floc? ■ ❑❑❑ I11000 11000 ■ ❑❑O • ❑ ❑ ❑ • ❑ ❑ ❑ • ❑ ❑ ❑ ■ O ❑ ❑ • ❑ ❑ ❑ • ❑ ❑ ❑ ▪ ❑ ❑ ❑ Permit: NC0003719 Owner - Facility: DAK Resins LLC - DAK Resins LLC - Fayetteville Inspection Date: 05/06/04 Inspection Type: Compliance Evaluation Secondary Clarifier Is the surface free of bulking ? Comment:There was three (3) feet of sludge in the clarifier with a tank depth of 14 (fourteen) feet. Pumps-RAS-DNA$ Are pumps in place? Are pumps operational? Are there adequate spare parts and supplies on site? Comment: Aeration Basins Mode of operation Type of aeration system 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? Are settleometer results acceptable? Comment: Disinfection Type of system ? Are cylinders secured adequately? Are cylinders protected from direct sunlight? Is there adequate reserve supply of disinfectant? Is ventilation equipment operational? Is ventilation equipment properly located? Is SCBA equipment available on site? Is SCBA equipment operational? Is staff trained is operating SCBA equipment? Is staff trained in emergency procedures? Is an evacuation plan in place? Are tablet chlorinators operational? Are the tablets the proper size and type? Number of tubes in use? (Sodium Hypochlorite) Is pump feed system operational? Is bulk storage tank -containment area adequate? (free of leaks/open drains) Is the level of chlorine residual acceptable? Is there adequate detention time Is the contact chamber free of growth, or sludge buildup? Comment: Pumn Station - Effluent Is the pump wet well free of bypass lines or structures? Is the general housekeeping acceptable? Is the wet well free of excessive grease? Are all pumps present? Yes No NA NF ■ ❑❑❑ Yes No NA NF ■ ❑❑o ■ O O ❑ ■ ❑❑❑ Yes No NA NF ▪ ❑ ❑ ❑ ■ ❑ ❑ ❑ 1 ❑ ❑ ❑ ■ ❑ ❑ ❑ ■ ❑❑❑ 1 ❑ ❑ ❑ pool" Yes No NA NF ❑ ❑ ■ ❑ ❑ 0 ■ ❑ ❑ ❑ • ❑ ❑ ❑ • ❑ ❑ ❑ • ❑ ❑ ❑ • ❑ ❑ ❑ ■ ❑ ❑ ❑ • ❑ ❑ ❑ • ❑ ❑ ❑ ■ ❑ ❑ ❑ • ❑ ❑ ❑■o ❑ ❑ • ❑ ❑ ❑ 1 ❑ ❑ ❑ • ❑ ❑ ❑■o ❑ ❑ • ❑ Yes Nn NA NF ❑ ❑ • ❑ ❑ O ■ O ❑ ❑ • ❑ ❑ 0.0 Permit: NC0003719 Owner - Facility: DAK Resins LLC - DAK Resins LLC - Fayetteville Inspection Date: 05/06/04 Inspection Type: Compliance Evaluation punin Station - Effluent Yes Nn NA NF Are all pumps operable? ❑ ❑ R ❑ Are float controls operable? ❑ ❑ ❑ Is SCADA telemetry available and operational? 0 0 • 0 Is audible and visual alarm available and operational? 0 0 • 0 Comment:Effluent is gravity fed to the Cape Fear River. Standby Power Yes No NA NF Is automatically activated standby power available? 0 0 • 0 Is generator tested weekly by interrupting primary power source? ❑ ❑ NO Is generator tested under load at least quarterly? 0 0 • 0 Was generator tested & operational during the inspection? 00.0 Do the generator(s) have adequate capacity to operate the entire wastewater site? 0 0 • 0 Does generator have adequate fuel? 0 0 • 0 Is there an emergency agreement with a fuel vendor for extended run on back-up power? ❑ ❑ ❑ Comment:Facility has a power feed into two different stations into the Wastewater Treatment Plant. I aboratory Yes No NA NF Are field parameters performed by certified personnel or laboratory? 1 ❑ ❑ ❑ Are all other parameters(excluding field parameters) performed by a certified lab? •❑ ❑ 0 Is the facility using a contract lab? .• 0 0 0 Are analytical results consistent with data reported on DMRs? 'N ❑ ❑ ❑ Is proper temperature set for sample storage (kept at 1.0 to 4.4 degrees Celsius)? •❑ ❑ ❑ Incubator (Fecal Coliform) set to 44.5 degrees Celsius+/- 0.2 degrees? 00E10 Incubator (BOD) set to 20.0 degrees Celsius +/- 1.0 degrees? ❑ ❑ ❑ Comment:All field parameters are analyzed by the Cape Fear facility for this site. The laboratory certification number is 139. Flow Measurement - Influent Yes No NA NF Is flow meter used for reporting? 00.0 Is flow meter calibrated annually? ❑ ❑ E ❑ Is flow meter operating properly? ❑ ❑ M ❑ (If units are separated) Does the chart recorder match the flow meter? 00.0 Comment: Flow Measurement - Effluent Yes No NA NF Is flow meter used for reporting? •❑ ❑ ❑ Is flow meter calibrated annually? 1 ❑ ❑ ❑ Is flow meter operating properly? •❑ ❑ ❑ (If units are separated) Does the chart recorder match the flow meter? ❑ ❑ ❑• Comment:Effluent flow meter was calibrated February 5, 2004 by facility staff. The % error was +/- 5% as per the calibration report. Re ,ord Keepinct Yes Nn NA NF Are records kept and maintained as required by the permit? •❑ ❑ ❑ Is all required information readily available, complete and current? 1 ❑ ❑ ❑ Are all records maintained for 3 years (lab. reg. required 5 years)? 1 ❑ ❑ ❑ Are analytical results consistent with data reported on DMRs? • 0 0 0 Are sampling and analysis data adequate and include: •❑ ❑ ❑ Dates, times and location of sampling • Name of individual performing the sampling • Permit: NC0003719 Owner - Facility: DAK Resins LLC - DAK Resins LLC - Fayetteville Inspection Date: 05/06/04 Inspection Type: Compliance Evaluation Record Keening Results of analysis and calibration Dates of analysis Name of person performing analyses Transported COCs Plant records are adequate, available and include O&M Manual As built Engineering drawings Schedules and dates of equipment maintenance and repairs Are DMRs complete: do they include all permit parameters? Has the facility submitted its annual compliance report to users? (If the facility is = or > 5 MGD permitted flow) Do they operate 24/7 with a certified operator 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? Is the facility description verified as contained in the NPDES permit? Does the facility analyze process control parameters, for example: MLSS, MCRT, Settleable Solids, DO, Sludge Judge, pH, and others that are applicable? Facility has copy of previous year's Annual Report on file for review? Comment:Laboratory records were reviewed for the months July, August, and September 2003 and compared to Discharge Monitoring Reports (DMRs). All records reviewed appeared to be accurate. Infit ent Samnlinq Is composite sampling flow proportional? Is sample collected above side streams? Is proper volume collected? Is the tubing clean? Is proper temperature set for sample storage (kept at 1.0 to 4.4 degrees Celsius)? Is sampling performed according to the permit? Comment: Ffflr lent 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 1.0 to 4.4 degrees Celsius)? Is the facility sampling performed as required by the permit (frequency, sampling type representative)? Comment: Aerobic Digester Is the capacity adequate? Is the mixing adequate? Is the site free of excessive foaming in the tank? Is the odor acceptable? Comment: Drying Beds Is there adequate drying bed space? Yes No NA NF • • • • ❑ ❑ ❑ • • • • ❑ ❑ ❑ ❑ ❑ • ❑ ❑ ❑ ■ ❑ ■ ❑❑❑ ■ ❑❑❑ 1000 1000 1000 1000. O ❑ ■ 0 Yes No NA NF O 0110 ❑ ❑ • ❑ ❑ ❑■❑ ❑ ❑ • ❑ ❑ ❑ • ❑ O 0110 Yes No NA NF 1000 1000 11000 1000 1000 ■ ❑ ❑ ❑ Yes No NA NF 1000 1000 1000 1000 Yes No NA NF :1000 Permit: NC0003719 Owner - Facility: DAK Resins LLC - DAK Resins LLC - Fayetteville Inspection Date: 05/06/04 Inspection Type: Compliance Evaluation Drying Reds Is the sludge distribution on drying beds appropriate? Are the drying beds free of vegetation? Is the site free of dry sludge remaining in beds? Is the site free of stockpiled sludge? Is the filtrate from sludge drying beds returned to the front of the plant? Is the sludge disposed of through county landfill? Is the sludge land applied? (Vacuum filters) Is polymer mixing adequate? Comment: Fffluent Pipe Is right of way to the outfall properly maintained? Are receiving water free of solids and floatable wastewater materials? Are the receiving waters free of solids / debris? Are the receiving waters free of foam other than a trace? Are the receiving waters free of sludge worms? If effluent (diffuser pipes are required) are they operating properly? Comment: Yes No NA NF MOOD MOOD 11000 ROOD . 000 11000 MOOD . 000 Yes No NA NF • ❑ 0 ❑ MOOD 11000 MOOD . 000 • ❑ ❑ ❑