NC0003719_Inspection_20070319

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 •
March 19, 2007
Mr. Donald Allbright,
Operator in Responsible Charge (ORC)
PO Box 1690
Fayetteville, NC 28312
SUBJECT: Compliance Evaluation Inspection Report (June 8, 2006)
DAK Resins LLC — Fayetteville
NC0003719
Cumberland County
Dear Mr. Allbright,
Enclosed you will find a copy of the Report for the Compliance Evaluation Inspection
that Trent Allen, DWQ Environmental Engineer, and I conducted on March 19, 2007. 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. • This facility was found
to be in Compliance with • permit, NC0003719. There was only one •suggestion . for this
inspection: that the periodic NIST thermometer crosschecks against the YSI 55 be tiled as a tool
for, reporting the true temperature' readings at the. effluent. Please make any corrections to the
YSI 5.5 readings when a crosscheck 'indicates a' difference of 0.1° C or greater between the two
• thermometers.
The facility Was well maintained. Your cooperation was greatly appreciated.
Dale Lopez
Environmental. Specialist
Enclosures: EPA Water Compliance Inspection Report
Check List for Field Parameters
cc: Anthony Hudson, D.A.K., Safety, Health, and Environment Manager
One .
NorthCarolina
2aturaij
North Carolina Division of Water Quality 225 Green Street— Suite 714 Fayetteville, NC 28301-5043 Phone [phone] Customer Service
Internet: .ncwaterquality.org FAX [phone]
An Equal opportunity/Affirmative Action Employer - 50% Recycled/10% Post Consumer Paper

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 I NI 2 II 31 NC0003719 111 121 07/03/19 117
Type Inspector Fac Type
18 CI 19I-I 201
Remarks
21111111111111111111111111111111111111111111111166
Inspection Work Days Facility Self -Monitoring Evaluation Rating B1 QA Reserved
671 1.0 169 70I-, I 711 I 72I! I 731174 751 I I I 11 I 180
1
Section B: Facility Data
Name and Location of Facility Inspected (For Industrial Users discharging to POTW, also include
POTW name and NPDES permit Number)
Cedar Creek Site
3468 Cedar Creek Rd
E Fayetteville NC 28301
Entry Time/Date
11:00 AM 07/03/19
Permit Effective Date
03/0 / 1•
Exit Time/Date
01:00 PM 07/03 19
Permit Expiration Date
06/1O/31
Name(s) of Onsite Representative(s)/Titles(s)/Phone and Fax Number(s)
///
Donald Ray Al.lbricht/ORC/910-433-8227/
Other Facility Data
Name, Address of Responsible Official/Title/Phone and Fax Number
Contacted ed
Anthony Hudson,-0 .o: 1690 Fayetteville NC 28302r/916.433.6=38;No
Section C: Areas Evaluated During Inspection (Check only those areas evaluated)
as necessary)
Permit ' Flow Measurement r4 Operations & Maintenance Records/Reports
and checklists
Facility Site Review a ; Effluent/Receiving Waters -", Laboratory
Section D: Summary of Finding/Comments (Attach additional sheets of narrative
(See attachment summary)
Name(s) an iignature(s) of Inspector(s) Agency/Office/Phone and Fax Numbers Date
Dale Lopez ' ` FRO i94/%910-433-•3300 Ext.712/
•
q att., 44/4 -7
Signature of Management Q A Reviewe Agency/Office/Phone and Fax Numbers Date
I /
EPA Form 3560-3 (Rev 9-94) Previous editions are obsolete.
Page # 1

NPDES
NC0003719
111 121
yr/mo/dgy
07/03/19
Inspection Type
17 18ICI
(cont:)
Section D: Summary of Finding/Comments (Attach additional sheets of narrative and checklists as necessary)
This facility appeared to be in compliance with its NPDES permit. There is a project in progress to install a,
permanent pump for transferring wastewater from the Emergency Spill Basin into the. EQ tank. It is
suggested that the periodic NIST thermoreter crosschecks against the YSI 55 be used as a tool for ,
reporting the true temperature readings atthe effluent. Please make the appropriate corrections to the YSI
• 55 readings when a crosscheck indicates a difference of 0.1 degrees Celsius or greater between the two
thermometers. Both of the effluent pumps were out -of -service that pump flow (at a rate of approximately
30,000 gallons per day) into the PWC sewer collection system and eventually intp the Fayetteville Public
Works Commission (PWC)Rockfish Creek Wastewater Treatment Plant. DAK is on a 'pretreatment.
program with PWC, and DAK's IUP number is 2116 RF.
•
Page #

Permit: NC0003719 Owner - Facility: Cedar Creek Site
Inspection Date: 03/19/2007 Inspection Type: Compliance Evaluation
Operations & Maintenance Yes No NA NE
Is the plant generally clean with acceptable housekeeping? p ❑ ❑
Does the facility analyze process control parameters, for ex: MLSS, MCRT, Settleable Solids, pH, DO, Sludge r ❑ ❑
Judge, and other that are applicable?
Comment:
Permit Yes No NA NE
(If the present permit expires in 6 months or less). Has the permittee submitted a new application? ® ❑ n 17
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? Eu❑ ❑ ❑
Is the inspector granted access to all areas for inspection? ❑ ❑ ❑
Comment:
Record Keeping Yes No NA NE
Are records kept and maintained as required by the permit? ® n ❑ ❑
Is all required information readily available, complete and current? p fl ❑ ❑
Are all records maintained for 3 years (lab. reg. required 5 years)? ❑ ❑ El
Are analytical results consistent with data reported on DMRs? ® ❑ ❑ ❑
Is the chain -of -custody complete? p ❑ ❑ ❑
Dates, times and location of sampling 0
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? ■ ❑ ❑ ❑
Has the facility submitted its annual compliance report to users and DWQ? • ❑ ❑
(If the facility is = or > 5 MGD permitted flow) Do they operate 24/7 with a certified operator on each shift? ❑ ❑ mi ❑
Is the ORC visitation log available and current? p ❑ ❑
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? ® ❑ ❑ El
Is a copy of the current NPDES permit available on site? • ❑ ❑ ❑
Page # 3

Permit: NC0003719 Owner - Facility: Cedar Creek Site
Inspection Date: 03/19/2007 Inspection Type: Compliance Evaluation
Record Keeping.
Facility has copy of previous year's Annual Report on file for review?
• Comment:
Effluent Pipe
Is right of way to the outfall properly maintained?
Are the receiving water free of foam other than trace amounts and other debris?
If effluent (diffuser pipes are required) are they operating properly?
Comment:
Flow Measurement - Effluent
# Is flow meter used for reporting?
Is flow meter calibrated annually?
Is the flow meter operational?
(If units are separated) Does the chart recorder match the flow meter?
Comment:
Grease Removal
# Is automatic grease removal present?
Is grease removal operating. properly?
Comment:
Secondary Clarifier -
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 return rate acceptable (low turbulence)?
Is the overflow clear of excessive solids/pin floc?
Is the sludge blanket level acceptable? (Approximately 'A of the sidewall depth)
Comment:
Yes No NA NE
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Page # 4

Permit: NC0003719 Owner - Facility: Cedar Creek Site
Inspection Date: 03/19/2007 Inspection Type: Compliance Evaluation
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?
Is the DO level acceptable?(1.0 to 3.0 mg/I)
Comment:
Laboratory
Are field parameters performed by certified personnel or laboratory?
Are all other parameters(excluding field parameters) performed by a certified lab?
# Is the facility using a contract lab?
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?
Incubator (BOD) set to 20.0 degrees Celsius +/- 1.0 degrees?
Comment:
Yes No NA NE
Ext. Air
Surface
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Page # 5

acne of.site to be Inspected: gei4v0 —
eld certification # (if applicable):'
PDES #: /Lk pe, .3 7/ 0/ Region:
Circle the parameter or parameters performed at this site.
.siUl Chlorine Settleable Solids, Conductivity,
Instrumentation:
Does the facility have the equipment necessary to analyze field paranieterS as circlecl above?
A pH meter H4e# No •
A Residual Chlorine meter
'DO meter
5—
A Cone for settleable solids
A thermometer or meter that measures tel_nperature.
s-s
Conductivity meter
1. Calibration/AnalySis:
. Is the pH meter calibrated with a/buffers and
checked with uffer each day of use'? •
No
.. For Total Res4 ual Chlorine, is a check standard
• 0,1g °"A / el /if /1 No
analyzed each day of 4se?.„--/y
Is the air calibration of the DO meter performed
each day of use? / 5 i 5-: s---
No
k For Settleable Solids, is 1 liter of sample
settled for 1 hour? Yes No
5. Is the temperature measuring device calibrated
annually against a certified thermometer? ( Ye- No
3. For Conductivity, is 'a calibration standard .
analyzed each day of use? Yes No
• Yes
Yes
Yes • •
No
No
No
No •

Yes
No.
IV. Documentation:
1. Is the date and time that the sample was collected documented
2. Is the sample site documented?
3. Is the sample collector documented?
•
4. Is. the analysis date and time documented?::::
5. Did the analyst sign the documentation?
6. Is record of calibration documented?
7. For Settleable Solids, is .sample volume and
1 hour time settling: time documented?
8. For Temperature, is the annual calibration of
the measuring .device documented?
Please submit a copy of this completed form to the Laboratory Certification Program.
DWQ Lab Certification
Chemistry Lab •
Courier # 52-01-01
FIELD INSPECTOR CHECKLIST REV. 04/23/2002