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Home My WebLink AboutNC0003719_Inspection_20100723AVA NCDENR North Carolina Department of Environment and Natural Resources Division of Water Quality Beverly Eaves Perdue Coleen H. Sullins Governor Director July 23, 2010 Anthony Hudson DAK Americas, LLC Post Office Box 1690. Fayetteville, North Carolina 28302 SUBJECT: Compliance Evaluation Inspection, July 21, 2010 DAK Americas, LLC Cedar Creek Facility Permit No: NPDES Permit # NC0003719 Cumberland County Dear Mr. Hudson: Dee Freeman Secretary Enclosed please find a copy of the Compliance Evaluation Inspection Report for the inspection conducted July 21, 2010. We are pleased to say that the facility was found to be in compliance with the terms and conditions set forth in NPDES Permit No. NC0003719 that were reviewed as part of the inspection. Mr. Allbright, Operator In Responsible Charge, was found to be very knowledgeable of the NPDES permit as well as items related to the operation and maintenance of the wastewater treatment facility (WWTF). Records reviewed were found to be very organized and neat. As part of the inspection a tour of the WWTF was conducted with only one item that should be addressed: -Observations of the eastern most aeration basin revealed vegetation growing from a seam or joint in the concrete above the water line. The vegetation should be removed and the seam or joint sealed to prevent the possible escape of wastewater and to prevent larger or woody vegetation from damaging the structure. Please notify the Fayetteville Regional Office at the letterhead address when this matter has been addressed. Also, as part of the inspection Item 6 of the permit cover letter was discussed concerning the Proposed Plastic Recycling Facility (PRF). Item 6, states in part, that "No later than 180 days prior to receiving waste from said PRF, DAK will provide a written report characterizing PFR wastes". A copy of the report was given to the writer at the time of the inspection. Further, it was confirmed from Mr. Joe Corporon, DWQ Point Source Branch that a copy of the report has been received by the DWQ Central Office. It should be noted that the PRF, known as Clear Path Recycling, is now in limited operation and is sending wastewater to the DAK WWTF. 225 Green St., Suite 714, Fayetteville, NC 28301-5043 Phone: 910-433-33001 FAX: 910-486-07071 Customer Service: 1-877-623-6748 Internet: www.ncwaterquality.org An Equal Opportunity \ Affirmative Action Employer NorthCarolina 1Vat M/ 44 Mr. Hudson July 23, 2010 Page 2 of 2 I would like to thank you, Mr. Allbright and Ms. Wike for your time during the inspection. Please refer to the attached report for further comments relating to the inspection. If you or your staff has questions or comments pertaining to the inspection please do not hesitate to contact me at (910) 433-3300. Enclosure: NPDES Inspection Report cc: Mir = raiat1e' y atOOliitc' Dale Lopez, FRO SWPS DWQ Central Files 225 Green St., Suite 714, Fayetteville, NC 28301-5043 Phone: 910-433-33001 FAX: 910-486-07071 Customer Service: 1-877-623-6748 Internet: www.ncwaterquality.org An Equal Opportunity \ Affirmative Action Employer Sincerely, f i.: 1 Paul Rawls Environmental Program Consultant NorthCarolina Naturally United States Environmental Protection Agency Washington, D.C. 20460 E PA 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 2 151 31 NC0003719 1 11 121 10/07/21 117 Type Inspector Fac Type 181 c1 191 SI 201 11 1111 111111166 Remarks 211111 11111111111111111111111111111111 Inspection Work Days Facility Self -Monitoring Evaluation Rating B1 QA 671 1 69 70I 51 711 1 721 NI --------- 1 1 1 1 1 1 1 80 --Reserved----- 73I 1 1 74 751 `` 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 Fayetteville NC 28301 Entry Time/Date 08:30 AM 10/07/21 Permit Effective Date 09/10/01 Exit Time/Date 12:30 PM 10/07/21 Permit Expiration Date 11/10/31 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 Facility Site Review Effluent/Receiving Waters 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 Paul E Rawls 1` �.�7 _ Division of Water Quality//919-733-5083/ 5083/ /' A �iJ �C% • Signature of Management Q A Reviewer Agency/Office/Phone and Fax Numbers' Date Belinda S Henson '(,1y �C•97.F,FRO WQ//910-433-3300 Ext.726/-21 —I 0 EPA Form 3560-3 (Rev 9-94) Previous editions are obsolete. Page # 1 NPDES NC0003719 I11 121 yr/mo/day 10/07/21 Inspection Type 117 181 CI (cont.) 1 Section D: Summary of Finding/Comments (Attach additional sheets of narrative and checklists as necessary) Mr. Allbright, Operator In Responsible Charge, was found to be very knowledgeable of the NPDES permit as well as items related to the operation and maintenance of the wastewater treatment facility (WWTF). Records reviewed were found to be very organized and neat. As part of the inspection a tour of the WWTF was conducted with only one item that should be addressed: -Observations of the eastern most aeration basin revealed vegetation growing from a seam or joint in the concrete above the water line. The vegetation should be removed and the seam or joint sealed to prevent the possible escape of wastewater and to prevent. larger or woody vegetation from damaging the structure. Please notify the Fayetteville Regional Office at the address noted on the coverletter when this matter has been addressed. As part of the inspection Item 6 of the permit cover letter was discussed concerning the Proposed Plastic Recycling Facility (PRF). Item 6, states in part, that "No later than 180 days prior to receiving waste from said PRF, DAK will provide a written report characterizing PFR wastes". A copy of the report was given to the writer at the time of the inspection. Further, it was confirmed from Mr. Joe Corporon, DWQ Point Source Branch that a copy of the report has been received by the DWQ Central Office. It should be noted that the PRF, known as Clear Path Recycling, is now in limited operation and is sending wastewater to the DAK WWTF. Floating oil/grease removal is accomplished by a closed loop of a specially formulated, flexible, hollow tube that floats on the water surface (influent). The skimmer continuously draws the oil -covered tube through scrapers and returns the clean tube to the water surface to gather more oil. The skimmed oil flows by gravity through the mounting system or a trough to the storage tank. The flexible, floating collector tube is able to "snake" over the water surface. Page # 2 Permit: NC0003719 Owner - Facility: Cedar Creek Site Inspection Date: 07/21/2010 Inspection Type: Compliance Evaluation Operations & Maintenance Yes No NA NE Is the plant generally clean with acceptable housekeeping? ■nnn Does the facility analyze process control parameters, for ex: MLSS, MCRT, Settleable Solids, pH, DO, Sludge ■ Judge, and other that are applicable? Comment: Facility analyzes pH, DO and Temp. 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: NPDES Permit expires October 31, 2011 See Summary Section of this report for comments addressing Special Conditions Flow Measurement - Effluent Yes No NA NE # Is flow meter used for reporting? • n n n Is.flow meter calibrated annually? • n n n Is the flow meter operational? • n n n (If units are separated) Does the chart recorder match the flow meter? ■ n n n Comment:' Calibration information was present and reviewed during inspection. Bar Screens. Yes No NA NE Type of bar screen a.Manual • b. Mechanical n. Are the bars adequately screening debris? • n n n Is the screen free of excessive debris? ■ n n n Is disposal of screening in compliance? • n n n Is the unit in good condition? • n n n Comment: Influent is screened via two screening plates with holes. Grease Removal Yes No NA NE # Is automatic grease removal present? ■ n n n Is grease removal operating properly? • n n n n n n Page # 3 Permit: NC0003719 Owner - Facility: Cedar Creek Site Inspection Date: 07/21/2010 Inspection Type: Compliance Evaluation Grease Removal Comment: Floating oil/grease removal is accomplished by a closed loop of a specially formulated, flexible, hollow tube that floats on the water surface. The skimmer continuously draws the oil -covered tube through scrapers and returns the clean tube to the water surface to gather more oil/grease. The skimmed oil/grease flows by gravity through the mounting system or a trough to the storage tank. The flexible, floating collector tube is able to "snake" over the water surface. Yes No NA NE Equalization Basins Yes No NA NE Is the basin aerated? ❑ ❑ • ❑ Is the basin free of bypass lines or structures to the natural environment? ■ ❑ ❑ ❑ 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? ■ ❑ ❑ ❑ Comment: Influent equalization is by the use of two (2) 660,000 gallon capacity tanks. Secondary Clarifier Yes No NA NE 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? i ❑ ❑ ❑ Is the return rate acceptable (low turbulence)? ■ ❑ ❑ ❑ Is the overflow clear of excessive solids/pin floc? MOOD Is the sludge blanket level acceptable? (Approximately % of the sidewall depth) ■ ❑ ❑ ❑ Comment: Sludge blanket was <1 foot deep and water column was extremely clear at time of the inspection. Aeration Basins Yes No NA NE Mode of operation Ext. Air Page # 4 Permit: NC0003719 Owner - Facility: Cedar Creek Site Inspection Date: 07/21/2010 Inspection Type: Compliance Evaluation Aeration Basins Yes No NA NE .Type of aeration system Fixed Is the basin free of dead spots? o ' n n n Are surface aerators and mixers operational? I n n n Are the diffusers operational?, n n • n Is the foam the proper color for the treatment process? ■ n n n Does the foam cover less than 25% of the basin's surface? ■ n n n Is the DO level acceptable? Nnnn Is the DO level acceptable?(1.0 to 3.0 mg/I) ■ n n ❑ Comment: DO level in the two aeration basins was reportedly 7.0 (western most basin) and 5.0 mg/I (eastern most basin). Pumps-RAS-WAS Yes No NA NE Are pumps in place? • ,n n n Are pumps operational? O n ❑ n Are there adequate spare parts and supplies on site? ■ n ❑ n Comment: Effluent Sampling Yes No NA NE Is composite sampling flow proportional? ■ n n ❑ Is sample collected below all treatment units? ■ n n n Is proper volume collected? ■ ❑ n n Is the tubing clean? 1 n n n # Is proper temperature set for sample storage (kept at less than or equal to 6.0 degrees Celsius)? ■ n n.. n Is the facility sampling performed as required by the permit (frequency, sampling type representative)? ■ n n n Comment: Sampler temperature was 2.0 degrees. Standby Power Yes No NA NE Is automatically activated standby power available? n n 1 n Is the generator tested by interrupting primary power source? n ❑ ■ n Is the generator tested under load? n n ■ n Was generator tested & operational during the inspection? ❑ n ■ n Do the generator(s) have adequate capacity to operate the entire wastewater site? ❑ n • n Is there an emergency agreement with a fuel vendor for extended run on back-up power? n n ■ n Page # 5 Permit: NC0003719 Owner - Facility: Cedar Creek Site Inspection Date: 07/21/2010 Inspection Type: Compliance Evaluation Standby Power Is the generator fuel level monitored? Comment: Facility power is dual feed. As this is an industrial facility if power is loss facility shuts down. 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: Contract Tabs are (1) TBL, (2) Element One, Inc., (3) Meritech, Inc. Yes No NA NE nDINO Yes No NA NE ■ nnn ■ nnn ■ nnn n n■n n n■n n nen Page # 6 DAK Americas August 18, 2010 Mr. Paul Rawls Environmental Program Consultant NCDENR Fayetteville Regional Office 225 Green Street, Suite 714 Fayetteville, NC 28382 Re: NPDES Permit NC0003719 Response to Compliance Evaluation Inspection on July 23, 2010 Dear Mr. Rawls: DENA F'RO AUG 2 3 2010 DWQ I am responding to the recommendation DAK Americas Cedar Creek Site received during a Compliance Evaluation Inspection you performed on July 23, 2010: Observation of vegetation growing around eastern aeration basin needed to removed and basin inspected for possible seam or crack issue. Vegetation was removed from around sides of aeration basin and an inspection performed the week of August 16, 2010. The basin has no seam in the area of the vegetation growth and no cracks were noted in the inspection. The vegetation growth was from bio-solid sludge buildup around the edge of the basin where the water level stops. The pic- ture shows the edge of aeration basin after the vegetation and sludge accumulation was removed. If anything else is required to close this action item, please let me know. I can be reached at (910) 433-8338 in my office or at (910) 489-3816 on my cell. Sincerely, Anthony Hudson Safety, Health, Environmental Manager Cedar Creek Site • 3216 Cedar Creek Rd. • Fayetteville, NC 28312 877-432-2766 (toll -free) • 910-433-8200 (phone) • 910-433-8366 (fax) www.dakamericas.com . Beverly Eaves Perdue Governor I r-, Resources North Carolina Department of Environment: andNatural Re`I`_ c � t�r �.ur-�.e,. Division of Water Quality Coleen H. Sullins Director September 3, 2010 Anthony Hudson DAK Americas, LLC Post Office Box 1690 Fayetteville, North Carolina 28302 SUBJECT: Response to Compliance Evaluation Inspection DAK Americas, LLC Cedar Creek Facility Permit No: NPDES Permit # NC0003719 Cumberland County L r`ornan Secretary Dear Mr. Hudson: This is to acknowledge receipt of your letter on August 23, 2010. Information received indicates that vegetation noted around the eastern aeration basin during the July inspection has been addressed. With your prompt action to address this issue we consider it closed. If you or your staff has questions or comments pertaining to this letter please do not hesitate to contact me at (910) 433-3300. cc: DWQ, FRO, DAK NPDES Inspection File DWQ Central Files ._ut= '�: svr-iir_'dI.- - %8a01-5Ou3 0. FA... E t.storner Sere ce.. 37 623-6748 Il(PI 1: \`: +•:1^; ::CWBicfi�UFiI[i�i.pt _cal It Paul 'Rawls Environmental Program Consultant One NCIrth ea i o 1 t n a fit/p-.1 '1 ', b'E"V Ce'ta