NC0003719_Inspection_20050729

NCDENR
North. Carolina. Department of Environment. and Natural Resources
Michael F. Easley, Governor
July 29, 2005
Mr. Stanley Carter
Service Complex Site Manager
PO Box 1690
Fayetteville, NC 28312
SUBJECT: Compliance Evaluation Inspection Report (July 26, 2005)
DAK Resins LLC — Fayetteville
NC00037.19
Cumberland County
Dear Mr. Carter,
William G. Ross Jr., Secretary
Alan W. Klimek, P.E:, Director
Coleen H. Sullins, Deputy Director
Division of Water Quality
Enclosed you will find a copy of the Report for the Compliance Evaluation Inspection
conducted on July 26, 2005. As part of the inspection a tour of the Wastewater Treatment Plant
was conducted. All observations are in Section D. Summary of Findings/Comments of this
inspection report. There was short-circuiting that was occurring under the secondary clarifier
weir. Please repair or replace the weir, and send a written response to DWQ-FRO by
September 1, 2005 with the Plan -of -Action for addressing the short-circuiting of flow under the
weir at the secondary clarifier. -
This facility was found to be in Compliance with permit NC0003719. The cooperation
of Mr. Donald Allbright, ORC, was greatly appreciated.
Sincere
Dale Lopez
Environmental S pecia is t
Enclosures: EPA Water Compliance Inspection Report
Check List for Field Parameters
cc: Donald Ray Allbright, ORC
225 Green Street — Suite 714, Fayetteville, North Carolina 28301-5043
Phone: [phone] FAX: [phone] Internet: www.enr.state.nc.us/ENRI
An Equal Opportunity' Affirmative Action Employer - 50 % Recycled i 10 Post Consumer Paper
NorthCarolina
Vaturaij

United States Environmental Protection Agency
E PA 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 u 2 U 3I NC0003719 1 11 121 05/07/26 117
Type Inspector Fac Type
18 Lci 19 U • 20 L—I
I I I I I I -1 I I I I I I 1 1.166
Remarks
211 I I I I I I I I I I I I I I I I I I I I I I I I 1 I I I I I
Inspection Work Days Facility Self -Monitoring Evaluation Rating B1 QA--------- --Reserved--- ----- —---- ------
671 2.0 169 701 J 71 I J 72 ILI 731 I 1 74 75I. 1 1 1 III 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 Americas, LLC - Cedar Creek Site
3468 Cedar Creek Rd
Fayetteville NC 28301
Entry Time/Date
09:30 AN 05/07/26
Permit Effective Date
03/04/01
Exit Time/Date
12:30 PM 05/07/26
Permit Expiration Date
06/10/31
Nanie(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
Contacted
Anthony Hudson, Manager Safety-Environmental,P.O. Sox 1690
Fayetteville NC 28302//910-433-8338/ No
Section C: Areas Evaluated During Inspection (Check only those areas evaluated)
Permit Flow Measurement Operations & Maintenance Records/Reports
Self -Monitoring Program Facility Site Review • Laboratory
Section D: Summary of Finding/Comments (Attach additional sheets of narrative and checklists as necessary)
(See attachment summary)
Name(s i nature(s) of Inspector(s) Agency/Office/Phone and Fax
Dale Lopez \) �� FRO WQ/ 910-486 1541 Ext.712/
4J
Numbers Dat
© J
Signature of Managemm�nt Q A Review r Agency/Office/Phone and Fax Numbers Date .
r�m ito .
--1/aT/c) 5
EPA Form 3560-3 (Rev 9-94) Previous editions are obsolete.

NPDES
NC0003719
111 121
yr/mo/day
05/07/26
17
Inspection Type
18 Li
1
Section D: Summary of Finding/Comments (Attach additional sheets of narrative and checklists as necessary)
There were several places that had short-circuiting under the weir of the secondary clarifier. Please repair
or replace the weir. Please send DWQ-FRO a letter with DAK's Plan -of -Action to address the short circuiting.

•
Permit Yes No NA NF
(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? MOOD
Comment:
Operations & Maintenance Yes No NA NF
Is the plant generally clean with acceptable housekeeping? •❑ ❑ ❑
Does the facility analyze process control parameters, for ex: MLSS, MCRT, Settleable Solids, pH, DO, Sludge Judge, •❑ ❑ ❑
and other that are applicable?
Comment:
Fqualization Basins Yes No NA NF
Is the basin aerated? 000.
Is the basin free of bypass fines or structures to the natural environment? 0 0 0 •
Is the basin free of excessive grease? 1 ❑ ❑ ❑
Are all pumps present? 0 0 • 0
Are all pumps operable? ❑ ❑ E ❑
Are float controls operable? ❑ ❑ E ❑
Are audible and visual alarms operable? • ❑ ❑ ❑
Is basin size/volume adequate? • ❑ ❑ ❑
Comment: The containment area is too small to contain the contents of the EQ tanks in case of rupture.
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? 1 ❑ ❑ ❑
Is the site free of weir blockage? • 0100
Is the site free of evidence of short-circuiting? 0 • 0 0
Is scum removal adequate? • ❑ ❑ ❑
Is the site free of excessive floating sludge? 1 ❑ ❑ ❑
Is the drive unit operational? • ❑ ❑ ❑
Is the return rate acceptable (low turbulence)? 1 ❑ ❑ ❑
Is the overflow clear of excessive solids/pin floc? 1 ❑ ❑ ❑
Is the sludge blanket level acceptable? (Approximately 'A of the sidewall depth) • ❑ ❑ ❑
Comment: Several places had short circuiting under the weir of the secondary clarifier.
Aeration Basins Yes No NA NF
Mode of operation - Ext. Air
Type of aeration system Surface
Is the basin free of dead spots? 1 ❑ ❑ ❑
Are surface aerators and mixers operational? 1 ❑ ❑ ❑
Are the diffusers operational? 1 ❑ ❑ ❑
Is the foam the proper color for the treatment process? 1 ❑ ❑ ❑
Does the foam cover less than 25% of the basin' s surface? 1 ❑ ❑ ❑
Is the DO level acceptable? ■ ❑ ❑ ❑
Is the DO level acceptable?(1.0 to 3.0 mg/I) • DOD
Comment:

j boratory Yes No NA NF
Are field parameters performed by certified personnel or laboratory? U ❑ ❑ ❑
Are all other parameters(excluding field parameters) performed by a certified lab? .000
Is the facility using a contract lab? 1 ❑ ❑ ❑
Is proper temperature set for sample storage (kept at 1.0 to 4.4 degrees Celsius)? 1 ❑ ❑ ❑
Incubator (Fecal Coliform) set to 44.5 degrees Celsius+/- 0.2 degrees? 00.0
Incubator (BOD) set to 20.0 degrees Celsius +/- 1.0 degrees? 0 0 • 0
Comment:
Flow Measurement - Effluent Yes No NA NF
Is flow meter used for reporting? 1 ❑ ❑ ❑
Is flow meter calibrated annually? • 0 0 0
Is the flow meter operational? 1 ❑ ❑ ❑
(If units are separated) Does the chart recorder match the flow meter? ❑ ❑ ❑ 1
Comment:
Record Keeping. Yes No NA NF
Are records kept and maintained as required by the permit? 1 ❑ ❑ ❑
Is all required information readily available, complete and current? .000
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
Is the chain -of -custody complete? • ❑ ❑ ❑
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 1
Transported COCs 0
Are DMRs complete: do they include all permit parameters? 1 ❑ ❑ ❑
Has the facility submitted its annual compliance report to users and DWQ? 0 0 0 •
(If the facility is = or > 5 MGD permitted flow) Do they operate 24/7 with a certified operator on each shift? ❑ ❑ E ❑
Is the ORC visitation log available and current? 0 0 0 •
Is the ORC certified at grade equal to or higher than the facility classification? 1 ❑ ❑ ❑
Is the backup operator certified at one grade less or greater than the facility classification? 1 ❑ ❑ ❑
Is a copy of the current NPDES permit available on site? 1 ❑ ❑ ❑
Facility has copy of previous year's Annual Report on file for review? ❑ ❑ ❑ 1
Comment:
Fffhuent Sampling Yes No NA NF
Is composite sampling flow proportional? 1 ❑ ❑ ❑
Is sample collected below all treatment units? • 0 0 0
Is proper volume collected? 1 ❑ ❑ ❑
Is the tubing clean? • 0 0 0
Is proper temperature set for sample storage (kept at 1.0 to 4.4 degrees Celsius)? 1 ❑ ❑ ❑
Is the facility sampling performed as required by the permit (frequency, sampling type representative)? 1 ❑ ❑ ❑
Comment:

Regional Field Inspectors Check List for Field Parameters
•
Jame of site to be Inspected: lJ `\
=ield certification # (if applicable): S 3 7 D Inspector:_
4PDES #:
e_ cot 3 7/,
Region:
Circle the parameter or parameters performed at this site.
esidual Chlorin
, Settleable Solids,
Conductivity,
II. Instrumentation:
A. Does the facility have the equipment necessary to analyze field parameters as circled above?
No
No.
3. 5 �, No
4. A Cone for settleable solids
Yes No
�Z 5S
5. A thermometer No WAG.' or meter that measures temperature. Yes j
No 11) /Ii7j
1.
2.
A pH. meter
A Residual Chlorine meter
DO meter
6. . Conductivity meter
III. Calibration/Analysis:
3;
1. Is the pH meter calibrated with a 2'buffers and
checked with a • • • • uffer each day of use?
2. For Total Resi• al Chlorine, is a check standard
analyzed eachday of se?L ,� �,�
3. Is the air calibration of the DO meter performed
each day of use?
4. For Settleable Solids, is 1 liter of sample
settled for 1 hour?
5. Is the temperature measuring device calibrated
annually against a certified thermometer?
•
6. For Conductivity, is a calibration standard
analyzed each day of use?
Yes
Yes
Yes
No
No

AtAi9,6"4/A-Q- 7Q".4 L'''',,,,-el- jil-dr:-'''9; ,,,
N` DAK Arv�ericas /‘'.
, OEMR - FAYE] I EV1LLF_ REGIONAL O -ICE FIBERS, MONOMERS & RESINS
August 16, 2005
Mr. Dale Lopez
NCDENR
225 Green Street
Suite 714
Fayetteville, NC 28301-5043
Reference: Compliance Evaluation Inspection Report (July 26, 2005)
Dear Mr. Lopez,
In your summary letter dated July 29, 2005, you requested a Plan -of -Action for
addressing the short-circuiting of the flow under the weir at the secondary clarifier. The
plan and scope of work are listed below.
Work Plan
1) Stop discharge flow from the clarifier.
2) Lower the level in the clarifier to gain access and expose the weir.
3) Prepare the area where the steel weir and concrete meet by pressure washing and
blasting.
4) Use a filler material in large crack areas.
5) Coat area with a joint sealer and a urethane coal tar sealer.
6) Allow joint sealer to cure for adequate bonding.
7) Bring the clarifier level back to operating and begin discharging.
The repairs are scheduled for September 2005 and are expected to be completed by
October 15, 2005. The repair process should take 2-3 days to complete to insure good
adhesion to the steel and concrete. Discharge flow will be -interrupted during the repair
process.
If you have further questions, please contact me.
anley Caarl?er
Services Complex Manager
910 433-8228, office
910 433-8289, fax