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Home My WebLink AboutNC0003719_Inspection_20090413NCDENR North Carolina Department of Environment and Natural Resources Division of Water Quality Beverly Eaves Perdue Coleen H. Sullins Dee Freeman Governor Director Secretary April 13, 2009 Anthony Hudson DAK Americas, LLC P.O. Box 1690 Fayetteville, NC 28302 SUBJECT: March 24, 2009 Compliance Evaluation Inspection DAK Americas, LLC Cedar Creek Site Permit No: NC0003719 Cumberland County Dear Mr. Hudson: Enclosed please find a copy of the Compliance Evaluation Inspection form from the inspection conducted on March 24, 2009. The Compliance Evaluation Inspection was conducted by Mark Brantley, Environmental Chemist, of the Fayetteville Regional Office. The facility was found to be in Compliance with permit NC0003719. The cooperation of Mr. Donald Albright, Facility's ORC, was greatly appreciated. As a reminder, preservation of the Waters of the State can only be achieved through consistent NPDES Permit compliance. Comments • The facility's log books and maintenance records appeared to be in order at the time of the inspection. • The monthly DMR for November 2008 was compared to laboratory bench sheets and reviewed for transcription errors. • The treatment units appeared to be maintained during the inspection. Please refer to the enclosed inspection report for additional observations and comments. If you or your staff have any questions, please call me at 910-433-3327. Sincerely, Mark Brantley Environmental Chemist Surface Water Protection Section Fayetteville Regional Office cc: Donald Albright, ORC Central Files Fayetteville Files NorthCarolina Naturally North Carolina Division of Water Quality/Aquifer Protection Section 225 Green St./ Suite 714 Fayetteville, NC 28301 Phone (910) 433-3300 FAX (910) 486-0707 Internet: h2o.enr.state.nc.us Customer Service 1-877-623-6748 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 1 51 31 N00003719 1 11 121 09/03/24 1 17 Type Inspector Fac Type 181 cl 191 s1 201 1 111111166 Remarks 21111111111111 1111 I11I 111111111111.11111111 Inspection Work Days Facility Self -Monitoring Evaluation Rating B1 QA Reserved 671 169 701 31 711 N I 721 1 731 1 1 74 751 1 1 1 1 1 1 180 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 34 68 Cedar Creek Rd Fayetteville NC 28301 Entry Time/Date 09:30 AM 09/03/24 Permit Effective Date 03/04/01 Exit Time/Date 12:00 PM 09/03/24 Permit Expiration Date 06/10/31 Name(s) of Onsite Representative(s)/Titles(s)/Phone and Fax Number(s) /// Donald Ray Allbright/ORC/910-433-8227/ Other Facility Data Name, Address of Responsible Official/Title/Phone and Fax Number Contacted Anthony Hudson,PO Box 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 • Sludge Handling Disposal • Facility Site Review Effluent/Receiving Waters 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 Mark Brantley FRO WQ//910-433-3300 Ext.727/ 'j- 3 U 6W4:7;5— ef Signature of Management Q A Reviewer Agency/Office/Phone and Fax Numbers Date j qie> q— I1-69 EPA Form 3560-3 (Rev 9-94) Previous editions are obsolete. Page # 1 NPDES yr/mo/day Inspection Type 31 NC0003719 111 12I 09/03/24 117 181 0 1 1 Section D: Summary of Finding/Comments (Attach additional sheets of narrative and checklists as necessary) , Comments • The facility's log books and maintenance records appeared to be in order at the time of the inspection. • The monthly DMR for November 2008 was compared to laboratory bench sheets and reviewed for transcription errors. • The treatment units appeared to be maintained during the inspection. Page # 2 Permit: NC0003719 Owner - Facility: Cedar Creek Site Inspection Date: 03/24/2009 Inspection Type: Compliance Evaluation Operations & Maintenance Yes No NA NE Is the plant generally clean with acceptable housekeeping? ® n ❑ Does the facility analyze process control parameters, for ex: MLSS, MCRT, Settleable Solids, pH, DO, Sludge ■ n n n 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 n n Is the facility as described in the permit? ■ n n n # Are there any special conditions for the permit? n n ■ n Is access to the plant site restricted to the general public? ■ n n n Is the inspector granted access to all areas for inspection? ■ n n n Comment: Record Keeping Yes No NA NE Are records kept and maintained as required by the permit? ■ n n n Is all required information readily available, complete and current? ■ n n n Are all records maintained for 3 years (lab. reg. required 5 years)? ■ n n n Are analytical results consistent with data reported on DMRs? ■ n n n Is the chain -of -custody complete? ® ❑ n ❑ 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? ■ n n n Has the facility submitted its annual compliance report to users and DWQ? n n ■ n (If the facility is = or > 5 MGD permitted flow) Do they operate 24/7 with a certified operator on each shift? 0 0 • n Is the ORC visitation log available and current? ■ n n Is the ORC certified at grade equal to or higher than the facility classification? ■ n ❑ Is the backup operator certified at one grade less or greater than the facility classification? ■ n n n Is a copy of the current NPDES permit available on site? ■ n n n Page # 3 Permit: NC0003719 Owner - Facility: Cedar Creek Site Inspection Date: 03/24/2009 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: Aerobic Digester Is the capacity adequate? Is the mixing adequate? Is the site free of excessive foaming in the tank? . # Is the odor acceptable? # Is tankage available for properly waste sludge? Comment: Drying_ Beds Is there adequate drying bed space? 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: 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? Yes No NA NE n n■n Yes No NA NE ■ nnn ■ nnn n n■n. Yes No NA NE ••nnn ■ nnn ■ nnn ■ nnn ■ nnn Yes No NA NE ■ nnn ■ nnn ■ -nnn ■ nnn ■ nnn ■ nn.n ■ nnn nn■n n nan Yes No NA NE ■ nnn ■ nnn ■ nnn n n■n Page # Permit: NC0003719 Owner - Facility: Cedar Creek Site Inspection Date: 03/24/2009 Inspection Type: Compliance Evaluation Flow Measurement - Effluent 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'/4 of the sidewall depth) 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? Is the DO level acceptable?(1.0 to 3.0 mg/I) Comment: Standby Power Is automatically activated standby power available? Is the generator tested by interrupting primary power source? Is the generator tested under load? Was generator tested & operational during the inspection? Yes No NA NE Yes No NA NE ■ nnn ■ nnn ■ nnn ■ nnn ■ nnn ■ nnn ■ nnn ■ nnn ■ nnn. ■ nnn • nnn Yes No NA NE Ext. Air Diffused ■ nnn ■ nnn n n■n • nnn ® n n ■ ■ nnn ■ nnn Yes No NA NE n n■n n n■n n HEW n n■n Page # 5 Permit: NC0003719 Owner - Facility: Cedar Creek Site Inspection Date: 03/24/2009 Inspection Type: Compliance Evaluation Standby Power Do the generator(s) have adequate capacity to operate the entire wastewater site? Is there an emergency agreement with a fuel vendor for extended run on back-up power? Is the generator fuel level monitored? Comment: The facility has two separate power feed lines that come to the plant. 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 less than or equal to 6.0 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: Facility uses TBL laboratory for its contract laboratory. 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)? Comment: Grease Removal # Is automatic grease removal present? Is grease removal operating properly? Comment: The unit is an oil skimmer. Pumps-RAS-WAS Are pumps in place? Are pumps operational? Are there adequate spare parts and supplies on site? Comment: The return pump station has three pumps total however one pump was down for repair at the time of the inspection. Yes No NA NE nn■n nn■n n n■n Yes No NA NE ■ nnn ■ nnn ■ nnn ■ nnn nn■n El main Yes No NA NE ■ 000 ■ nnn ■ nnn ■ nnn ■ nnn ■ nnn Yes No NA NE ■ nnn ■ nnn Yes No NA NE ■ nnn ■ nnn n n■n Page # 6