NC0003719_Inspection_20030328

Arin
NCDENR
North Carolina Department of Environment and Natural Resources
Michael F. Easley, Governor
March 28, 2003
Mr. Manhar Patel, Site Manager
Monsanto Company
3468 Cedar Creek Road
Fayetteville, NC 28301
SUBJECT: Compliance Evaluation Inspection
Monsanto Company
Wastewater Treatment Plant
NPDES Permit No. NC0003719
Cumberland County
Dear Ms. Small:
r•-/-;..r;
William G. Ross, Jr., Secretary
Alan Klimek, P.E., Director
Division of Water Quality
Enclosed is a copy of the Compliance Evaluation Inspection conducted March 26, 2003.
As part of the inspection a tour of the Wastewater Treatment Plant was conducted. All observations
and recommendations are in Part D. Summary of Findings/Comments of this inspection report. The
cooperation of Mr. Donald Allbright, Grade IV ORC was appreciated. During the inspection a copy
of the NPDES Compliance Reminders were reviewed and left with Mr. Allbright. As a reminder
preservation of the Waters of the State can only be acquired through consistent NPDES permit
compliance.
Please review the attached report. If you or your staff have any questions do not hesitate •
to contact me at 910-486-1541.
Sincerely, rt
Belinda S. Henson
Environmental Chemist
/bsh
Enclosures
cc: Mr. Donald Allbright, ORC, Monsanto Company
Fayetteville Regional Office
225 Green Street — Suite 714, Fayetteville, North Carolina 28301-5043
Phone: [phone]/FAX: [phone] Internet: www.enrstate.nc.us/ENR
An Equal Opportunity 1 Affirmative Action Employer — 50% Recycled 1 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 Ltd 2 l�l 3I NC0003719 I11 121 03/03/26 117
LJ LJ
Type Inspector Fac Type.
18'^U t 19t 20�
U
Remarks
2,IIIIIIII 11111111111111111IIIIIIIIIIII1]IIIIIIII66
Inspection Work Days Facility Self -Monitoring Evaluation Rating B1 QA Reserved------------- ------
67 1 169 70 t , LJ ( 71 nI 72 rI 731174 7511 80
1111111
Section B: Facility Data
Name and Location of Facility Inspected (For Industrial Users discharging to POTW, also include
POTW name and NPDES permit Number)
Monsanto Company
3468 Cedar Creek Road
Fayetteville NC 28302
Entry Time/Date
01:15 PM 03/03/26
Permit Effective Date
02/02/01
Exit Time/Date
04:20 PM 03/03/26
Permit Expiration Date
06/10/01
Name(s) of Onsite Representative(s)/Titles(s)/Phone and Fax Number(s)
Donald Allbright//910-433-4237/
Donald Allbright//910-433-4237/
Other Facility Data
Name, Address of Responsible Official/Title/Phone and Fax Number
Contacted
Lonnie Morgan,3468 Cedar Creek Road Fayetteville NC 28301//910-323-3 000/
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
Section D: Summary of Finding/Comments (Attach additional sheets of narrative and checklists as necessary)
The facility accepts wastewater from the following industries located on the complex site: Dupont and
DAK. The influent flocs is generated from these two facilities. The Monsanto site has been bulldozed
down and debris has been removed from the site.
The EQ (Equalization) Basin contains only rainwater and some wastewater from aeration basin )#1. The
wastewater from the EQ basin is fed back i.nto the plant at a slow pace.
(cont.)
The influent travels to two (2) 650,000 gallon equalization tanks. The
Name(s) and Signature(s) of Inspector(s) Agency/Office/Phone and Fax Numbers Date
Belinda S Henson ✓ , 11, %� �c-"iz�E11--r' FRO ;iQ//910-468 1541/910-486 0707 ,3 I V `U J
^
Signature of Manag" enQ A
Paul E Rawls �
eviewer Agency/Office/Phone and Fax Numbers Date
910-468-1541/910-486-0707
EPA Form 3560-3 (Rev 9-94) Previous editions are obsolete.

3I
NPDES
NC0003719
111 12
yrlmo/day
03/03/26
117
Inspection Type
18 icj
(cont.) 1
Section D: Summary of Finding/Comments (Attach additional sheets of narrative and checklists as necessary)
flow travels from the tanks to an area where pH adjustment, oil skimming and addition of ammonia. Steam
is also added to increase the temperature in this area to give the bacteria a warmer climate to enhance
growth and reproduction. Some aeration is added at the end of the pH adjustment area. The tank for the
oil skimmer had been repaired since the last inspection dated March 5,:2002 and the containment area had
been, cleaned.
Aeration Basin #1 is no longer used and only contains some rainwater. All sludge and wastewater had been
removed. Aeration Basin #2 appeared to be operating adequately. All five (5) aerators and two (2)
mixers were operational. The domestic waste stream is introduced into AB #2 through a comminutor first
to remove any paper products or debris. The most recent Mixed Liquor Suspended Solids (MLSS) results
were 4000 mg/L. A floculant and coagulant is added to the MLSS before'it flows to the clarifier to
assist in settling.
Clarifier 41 was operational with 2 feet of sludge with a tank depth of 15 feet. The scum arm and weirs
around.the clarifier appeared to have paint worn from.numerous areas. :***THESE AREAS SHOULD BE REPAIRED
IN THE NEAR FUTURE TO ELIMINATE FURTHER COSTS AND TO ENSURE PROPER MAINTENANCE IS COMPLETED AS PER THE
NPDES PERMIT.*** Clarifier #2 has been completely removed from the site.
• The effluent appeared to be free of solids or foam.
The effluent composite sampler refrigerator temperature was approximately 3.8 degrees C. The acceptable
temperature range of samples during storage is 1.0 - 4.4 degrees C.
The Fischer Porter effluent flow meter was calibrated by staff October 23, 2002. ***A RECOMMENDATION
WOULD BE TO DOCUMENT THE % ERROR OR TOLERANCE IN THE CALIBRATION RECORDS.***
The facility has two digesters but are presently only utilizing one of those. After sludge is digested
it is pumped into the aerated biosolids holding basin. Sludge is land applied under permit # WQ0001959.
Synagro is the contract company which land applies the sludge. The facility is also utilizing its three
(3) of the four (4) sand drying beds located at the plant. 'One (1) sand drying bed is inoperable due to
underdrain problems. Biosolids holding basin was approximately M full and supernatant was in the process
of being taken from the basin.
All maintenance records are recorded and kept by maintenance staff. Work orders are generated and
completed by a computer program. All preventive maintenance is flagged within this computer system.
The facility does various process control analyses which include: MLSS, F/M, SVI and etc. from the
aeration basin.
***THE ORC LOG WAS REVIEWED AND A RECOMMENDATION WOULD BE THAT THE ORC INITIAL EACH DAY HE VISITS THE
PLANT.*** Presently Mr. Allbright documents yes/no on his visits to the WWTP.
The Backup ORCs are the following staff: Conrad Lyle, Sharon Frost, and Royce Walters.
A compliance evaluation for the period January 2002 through December 2002 revealed a daily maximum BOD
exceedance for the month of December.
All NPDES permit required parameters are analyzed by the commercial laboratory Similabs. The facility is
not certified for Field Parameters.
Laboratory records were reviewed for the months of April and October 2002 and compared to Discharge
Monitoring Reports (DMRs). All data reviewed appeared to be accurate.

Section D: Summary of Findings/Comments
Brief Facility Description:
A 1.25 MGD WWTP consisting of flow equalization, spill basin, p1-1 austment, oil skimming,
coniminutor, dual aeration basins, clarifier, parshall flume, sludge pump station dual aerobic
di esters aerated biosolids holding basin biosolids drying beds.
FACILITY SITE REVIEW
63) No N/A 1. Treatment units properly operated and maintained.
e§) No N/A 2. Standby power or other egiiivalent'provision provided.
es No N/A 3. Adequate alarm system for power or equipment failure available.
4.- Sludge disposal procedures appropriate:
(Yews No N/A a. Disposal of sludge according to regulations
es ` No N/A b. State approval for sludge disposal received.
CS T) No N/A 5. Sufficient sludge disposed of to maintain treatment process equilibrium.
No N/A 6. The ORC and Backup Operator are officially designated with
NCDENR/DWQ Training and Certification Unit.
es) No N/A 7. Adequate spare parts and supplies inventory maintained.
(Yes`' No N/A 8. Plant has general safety structures such as rails around or covers over
tanks, pits, or wells.
sNo N/A 9. Plant is generally clean, free from open' trash areas.
10. Screening:
Yes No J? a. Manual
Yes No N/A b. Mechanical
Yes No N/A c. Buildup of debris
Yes No N/A d. Screenings properly disposed of.
11. Grit Removal:
Yes No0) a. Excessive organic content in the grit chamber
Yes No N/A b. Excessive odors
Yes No N/A c. Grit properly disposed of.

Page 2
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
No
No
No
No
No
No
No
No
No
No
No
No
No
No
No
No
No
No
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
Yes psi' N/A
Yes N/A
Yes OgZid. N/A
Yes N/A
Yes N/A
Yes No VS.
Yes No &�
Yes No WA
Yes No N/A
Yes No N/A
Yes No N/A
Primary clarifier:
a. Excessive gas bubbles
b. Black and' odorous wastewater
c. Poor suspended solids removed
d. Excessive "buildup of solids in center well of circular clarifier `.
e. Weirs level
f. Weir blockage
g. Evidence of short circuiting
h.. Lack of adequate scum removal
i. Excessive floating sludge
Broken sludge scraper.
Trickling Filter:
a. Trickling f lter ponding(indicating clogged' media)
b. Leak at center column of trickling filter's distribution arms
c. Uneven distribution of flow on trickling filter surface
d. Uneven or discolored growth
e. Excessive sloughing of growth
f. Odor
Clogging of trickling filter's distribution arrn orifices
Filter flies, worms, or snails.
g,
h.
14. Activated Sludge Basins/Oxidation Ditches:
a.
b.
c,
d.
e.
f.
Dead spots
Failure of surface aerators
Air rising in clumps
Dark foam or bad color
Thick billows of white, sudsy foam
Air rising unevenly
g. Excessive air leaks in compressed air piping.
15. Stabilization Ponds/Lagoons:
a. Excessive weeds including duckweed in stabilization ponds
b. Dead fish or aquatic organisms
c. Buildup of solids around influent pipe
d. Excessive scum on surface.

Page 3
16. Secondary Clarifier:
Yes N/A a. Excessive gas bubbles on surface
Yes (Nft3 N/A b. Level overflow weirs
Yes Ni3) N/A c. Weir blockage
Yes 0, N/A d. Evidence of short circuiting
Yes ISO N/A e. Excessive buildup of solids in center well of circular clarifier
Yes No N/A f. Pin floc in overflow Some_ 0 a 1-. e'X c. e. s i „re
sNo N/A g. Effective scum rake
Yes aio? N/A h. Floating sludge on surface
Yes a N/A i. Excessive high sludge blanket
Yes ea N/A j. Clogged sludge withdrawal ports on secondary clarifier.
17. Filtration:
Yes No QW . a. Filter surface clogging
Yes No N/A b. Short filter run
Yes No N/A c. Gravel displacement of filter media
Yes No N/A d. Loss of filter media during backwashing
Yes No N/A e. Recycled filter backwash water in excess of 5 percent
Yes No N/A f. Formation of mudballs in filter media.
18. Chlorination Unit:
Yes Nod a. Sludge buildup in contact chamber
Yes No N/A b. Gas bubbles.
Yes No N/A c. Floating scum and/or solids
Yes No N/A d. Adequate ventilation of chlorine feeding room and storage area
Yes No N/A e. NIOSH-approved 30 minute air pack
Yes No N/A f. All standing chlorine cylinders chained in place
Yes No N/A g. All personnel trained in the use of chlorine
Yes No N/A h. Proper chlorine feed, storage, and reserve supply.
Yes No gi, 19. Ultraviolet radiation disinfection present and in use.
20. Dechlorination:
Yes No 44i a. Proper storage of sulfur dioxide cylinders
Yes No N/A b. Adequate ventilation of sulfur dioxide feeding room
Yes No N/A c. Automatic sulfur dioxide feed or feedback control operating
properly.
Yes N/A
Yes (go> N/A
Yes co N/A\
Yes No/
21. Aerobic Digester:
a. Excessive foaming in tank
b. Noxious odor
c. Mechanical aeration failure
d. Clogging of diffusers.

Page 4
Yes No ! .�
Yes No N/A
22. Anaerobic Digester:
a. Floating cover tilting
b. Gas burner operative
23. Sludge Drying and/or disposal:
Yes (TO N/A a. Poor sludge distribution on drying beds
Yes N/A b. Vegetation in drying beds
Yes No% N/A c. Dry sludge remaining in drying beds
No N/A d. Dry sludge stored on site
()rev No N/A e. Filtrate from sludge drying beds returned to front of plant
Yes No N/A f. Sludge disposal through county landfill.
' ,!SieNo N/A g. Sludge land applied.
24. Filter Press:
Yes No �Va� a. High level of solids in filtrate from filter presses or vacuum filters
Yes No N/A b. Thin filter cake caused by poor dewatering
Yes No N/A c. Sludge buildup on belts and/or rollers of filter press
Yes No N/A d. Excessive moisture in belt filter press sludge cake.
Yes No
Yes No N/A
Yes No N/A
Yes CNa N/A
Yes cso) N/A
s') No N/A
CYes' No N/A
eil No N/A
Yes Q N/A
Yes igo' N/A
Yes N/A
Yes No G/2
Yes No N/A
25. Polishing Ponds or Tanks:
a. Objectionable odor, excessive foam, floating solids, or oil sheens on
water surface
b. Solids or scum accumulations in tank or at side of pond
c. Evidence of bypassed polishing ponds or tanks because of low
capacity.
26. Plant Effluent:
a. Excessive suspended solids, turbidity, foam, grease, scum, color, and
other macroscopic particulate matter present
b. Potential toxicity (dead fish, dead plant at discharge)
c. Outfall discharge line easily accessible.
27. Flow Measurement:
a. Proper placement of flow measurement device
b. Flow meter calibrated
c. Buildup of solids in flume or weir
d. Broken or cracked flume or weir
e. Clogged or broken stilling wells
f. Weir plate edge corroded or damaged
g. Flow measurement error less than 10%.

Page 5
Yes No N/A
Yes No N/A
Yes No N/A
Yes No N/A
28. Sampling:
a. Sampling and analysis completed on parameters specified by permit
b. Composite sample temperatures maintained at 4 degrees Celsius or
less (but above freezing) during sampling
c. Contract laboratory used for sample analysis
d. •Effluent composite samples obtained 'are flow proportional.
No N/A
N/A
RECORDKEEPING AND REPORTING
1. Records and reports maintained as required by permit
2. All required information available, complete, and current.
No N/A 3. Records maintained for 3 years and all sludge records maintained for 5
years.
No N/A 4. Analytical results consistent with data reported on DMRs.
Yes No N/A
Yes No N/A
Yes No N/A
Yes No N/A
Yes No N/A
5. Sampling and analyses data adequate and include:
a. Dates, times, and ideation of sampling
b. Name of individual perfatning sampling
c. Results of analyses and calibration
d. Dates of analyses.
e. Name of person perforining analyses.
6. Monitoring records adequate and include:
Yes No N/A a. Monitoring charts kept for 3 years
Yes No N/A b. Flowmeter calibration records kept for 3 years.
• Yes No N/A 7. The pH meter is calibrated daily with two buffers and checked with a
third buffer and properly documented.
Yes No N/A 8. Expiration dates of pH buffers adequate.
Yes No N/A 9. All thermometers used in NPDES permit reporting is calibrated
annually with an NIST certified thermometer or a traceable
thermometer annually and documented.
Yes No N/A -10.. The following NPDES, permit required parameters are analyzed on site:
pH, Temperature, Dissolved Oxygen and Chlorine Residual,

Page 6 -
Yes No c i ?
Yes No CINIA
Yes
11. The NPDES permit required parameter Total Chlorine Residual is
analyzed by approved method.
12. BOD incubator temperature maintained at 20 +/- 1 Degrees Celsius
and the temperature maintained in a log for every day of operation.
No ga) 13 Fecal coliform incubator maintained at 44.5 +1- 0,2 Degree Celsius and
the temperature maintained in a log for every day of operation.
ces; No N/A
Yes) No N/A
Yes No N/A
Yes No N/A
Yes No 6/47
(Yes No N/A
Yes No
Yule's) No N/A
e No N/A
14. Plant records adequate and include:
a. 0 & M Manual- S5 ry .1
b. "As -built" engineering drawings
c. Schedules and dates of equipment
d. Equipment data cards.
i'r1 r;if O jc, ,41osi it
vyl Q , �1 K
maintenance repairs
15. Permitteeismeeting compliance schedule.
16. DMRs complete and include all NPDES permit required parameters.
17. The facility has a permitted flow greater than 5 MGD and is required
to operate seven days per week 24 hours a day.
18. ORC visitation logs available and current.
19. ORC certified at a level equal to or greater than the classification of
the wastewater facility.
No N/A 20.
No N/A 21.
No N/A 22.
61 No N/A
Backup Operator certified at one level less than the classification of
the wastewater facility or greater.
Current copy of the complete NPDES permit on site.
Facility description verified as contained in NPDES permit.
23. Facility analyzes process control parameters for example: MLSS,
MCRT, Settleable Solids and others that are applicable.
Yes No N .1A) 24. Industrial Waste Surveys (IWS) sent to all possible Significant
Industrial Users (SIUs) within the last five years (especially new
industries).
Revised 7/16/01
by Belinda Henson