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Home My WebLink AboutNC0003719_Inspection_201106024EVA NCDENR North Carolina Department of Environment and Natural Resources Division of Water Quality Beverly Eaves Perdue Coleen H. Sullins Dee Freeman Governor Director Secretary June 2, 2011 Mr. Donald Allbright (ORC) DAK Americas LLC Cedar Creek Site PO Box 1690 Fayetteville, NC 28302 SUBJECT: Compliance Evaluation Inspection Report for the June 1, 2011 inspection DAK Americas LLC — Fayetteville NC0003719 Cumberland County Dear Mr. Allbright, Enclosed you will find a copy of the Compliance Evaluation Inspection (CEI) report for the routine annual inspection that I performed on June 1, 2011 at the DAK Wastewater Treatment Plant. 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. On the day of my inspection, the wastewater treatment plant appeared to be in compliance with the NPDES permit. I appreciate the time and professional courtesy that you extended during the inspection. No additional response is necessary from your office to the DWQ-Fayetteville Regional Office concerning this CEI report. Please contact me at (910) 433-3312 if you have any questions or comments. Sincerely, Dale Lopez Environmental Specia ist Enclosures: EPA Water Compliance Inspection Report BIMS Compliance Evaluation Check List Check List for Field Parameters cc: Anthony Hudson, DAK Safety, Health, and Environment Manager FRO files (Mark Brantley) 225 Green St, Suite 714, Fayetteville, NC 28301-5043 Phone: 910-433-3300 \ FAX; 910-486-0707 ( Customer Service: 1-877-623-6748 Internet: www.ncwaterquality.org An Equal Opportunity \ AYrmative Action Employer One North Carolina Naturally United States Environmental Protection Agency EWashington, D.C. 20460 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 15I 31 NC0003719 ' 111 121 11/06/01 117 Type Inspector Fac Type 181 CI 19I sI 20I II Remarks 21111III1I1II1I1IIII11II1I11IIIIIIIIIII1I11I111II66 Inspection Work Days Facility Self -Monitoring Evaluation Rating B1 QA 67I 2.0 169 70I 41 711 I 72111 -----------Reserved------ 731 I 174 79 I I 1 I 1 1 180 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 10:00 AM 11/06/01 Permit Effective Date 09/10/01 Exit Time/Date 03:00 PM 11/06/01 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 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 Sign (s) of Inspector(s Agency/Office/Phone and Fax Numbers Dale Lopez-(_t FRO WQ//910-433-3300 Ext.712/ Date /9/..? / i Signature of Management Q Revie er n Agency/Office/Phone and Fax Numbers Date G /3// 1 EPA Form 3560-3 (Rev 9-94) Previous editions are obsolete. Page # 1 3I NPDES NC0003719 111 12I yr/mo/day 11/06/01 Inspection Type 117 18I C (cont.) 1 Section D: Summary of Finding/Comments (Attach additional sheets of narrative and checklists as necessary) This facility was found to be in compliance with NPDES Permit NC0003719. All units were in service. The secondary clarifier generally maintained a sludge blanket level of 2 to 4 feet. On the day of this inspection, the sludge blanket level was 2 feet. The 002 DMR for January 2011 was checked for errors in transposing and calculation. There were no errors found. DAK uses TBL as their commercial laboratory, and TBL contracts out the aquatic toxicity to Meritech. The metals were sent from TBL to Element ONE for analyses. Page # 2 Permit: NC0003719 Owner - Facility: Cedar Creek Site Inspection Date: 06/01/2011 Inspection Type: Compliance Evaluation Operations & Maintenance Yes No NA NE Is the plant generally clean with acceptable housekeeping? • n n 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: Process control parameters were MLSS, MCRT, Settleable Solids, pH, DO, Sludge Judge, and DOUR. 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 Is the inspector granted access to all areas for inspection? •000 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)? R n n n Are analytical results consistent with data reported on DMRs? ■ n n n Is the chain -of -custody complete? ■ n n 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? n n ■ n Is the ORC visitation log available and current? ■ n n n Is the ORC certified at grade equal to or higher than the facility classification? ■ n n n Is the backup operator certified at one grade less or greater than the facility classification? ■ n n n Page # 3 Permit: NC0003719 Owner - Facility: Cedar Creek Site Inspection Date: 06/01/2011 Inspection Type: Compliance Evaluation Record Keeping Is a copy of the current NPDES permit available on site? Facility has copy of previous year's Annual Report on file for review? Comment: DAK is permitted for a flow of 0.5 MGD. They operate 24/7 with certified operators. 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: The effluent was a pipe source under water into the Cape Fear River. 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: This unit has two oil skimmers that are located at the pH pit. 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? Yes No NA NE • 000 ■ ❑❑❑ Yes No NA NE ■ nnn ■ ❑❑❑ ❑❑■❑ Yes No NA NE ■ nnn ■ nnn ■ ❑❑❑ ❑n❑■ Yes No NA NE ■ ❑❑❑ ■ ❑❑❑ Yes No NA NE ■ ❑❑❑ ■ ❑❑❑ 1nnn • 000 annn ■ ❑❑❑ ■ ❑❑❑ ■ nnn ■ n❑n ■ ❑❑❑ Page # 4 Permit: NC0003719 Owner - Facility: Cedar Creek Site Inspection Date: 06/01/2011 Inspection Type: Compliance Evaluation Secondary Clarifier Yes No NA NE Is the sludge blanket level acceptable? (Approximately % of the sidewall depth) ■ n n n Comment: Aeration Basins Yes No NA NE Mode of operation Ext. Air Type of aeration system Surface Is the basin free of dead spots? ■ n n n Are surface aerators and mixers operational? ■ 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? ■ n n n Is the DO level acceptable?(1.0 to 3.0 mg/I) ■ n n n Comment: Aeration Basin AB-1 was being used. The other aeration basin (AB-2) was primarily used as an aerobic digester. Laboratory Yes No NA NE Are field parameters performed by certified personnel or laboratory? ■ n n n Are all other parameters(excluding field parameters) performed by a certified lab? ■ n n # Is the facility using a contract lab? ■ n n n # Is proper temperature set for sample storage (kept at less than or equal to 6.0 degrees Celsius)? ■ n n n Incubator (Fecal Coliform) set to 44.5 degrees Celsius+/- 0.2 degrees? ❑ ❑ ■ n Incubator (BOD) set to 20.0 degrees Celsius +/-1.0 degrees? nnion Comment: Effluent Sampling Yes No NA NE Is composite sampling flow proportional? ■ n n n Is sample collected below all treatment units? Er -inn Is proper volume collected? ■ n n n Is the tubing clean? ■ 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: Page # 5 Permit: NC0003719 Owner - Facility: Cedar Creek Site Inspection Date: 06/01/2011 Inspection Type: Compliance Evaluation Aerobic Digester Yes No NA NE 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 Yes No NA NE 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? n ❑ • ❑ # Is the sludge land applied? ■ ❑ ❑ ❑ (Vacuum filters) Is polymer mixing adequate? ■ ❑ ❑ ❑ Comment: McGill handles the hauling and composting of the dried sludge from the sludge storage area and from the,aerobic digester. Chemical Feed Yes No NA NE Is containment adequate? ■ ❑ ❑ ❑ Is storage adequate? ' ■ ❑ ❑ Are backup pumps available? ai.nnn Is the site free of excessive leaking? ■ ❑ ❑ ❑ Comment: Standby Power Yes No NA NE 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? ❑ ❑ ■ ❑ Do the generator(s) have adequate capacity to operate the entire wastewater site? ❑ ❑ ■ ❑ Page # 6 Permit: NC0003719 Owner - Facility: Cedar Creek Site Inspection Date: 06/01/2011 Inspection Type: Compliance Evaluation Standby Power Yes No NA NE Is there an emergency agreement with a fuel vendor for extended run on back-up power? n 0 • 0 Is the generator fuel level monitored? ❑ n ■ n Comment: There are dual electrical feed lines from Progress Energy. There are no generators for the VVVVTP. Page # 7 Regional Field Inspectors Check List for Field Parameters Name of site to be Inspected: DAK Date June 1, 2 Field certification # (if applicable): 5378 Inspector: Dale Lopez NPDES #: NC0003719 Region: FRO I. Circle the parameter or parameters performed at this site. Residual Chlorine , Settleable Solids, II. Instrumentation: pH DO , Conductivity, Temperature A. Does the facility have the equipment necessary to analyze field parameters as circled above? 1. A pH meter HACH Senslon 2 2. A Residual Chlorine meter 3. DO meter 4. A Cone for settleable solids HACH Colorimeter fYS 155 Yes No Yes No NYes No Yes No 5. A thermometer or meter that measures temperature. fres No frSI 55 6. Conductivity meter III. Calibration/Analysis: 1. Is the pH meter calibrated with 3 buffers and checked with a fourth buffer each day of use? 2. For Total Residual Chlorine, is a check standard analyzed each day of use? 3. Is the air calibration of the DO meter performed each day of use? Yes No Yes Yes Yes 4. For Settleable Solids, is 1 liter of sample settled for 1 hour? Yes 5. Is the temperature measuring device calibrated annually against a certified thermometer? 6. For Conductivity, is a calibration standard analyzed each. day of use? NYes Yes No No No No No No NE NE NE 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? Comments: Yes hYes fres Yes fres fres Yes lYes No No No No No No No No pH 4 Buffer expired on 11/2012 pH 7 Buffer expired on 12/2012 pH 10 Buffer expired on 6/2012 Second pH 7 Buffer check, expired on 2/2012 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