NC0005321_Inspection_20030429

Al"A
NCDENR
North Carolina Department of Environment and Natural Resources
Michael F. Easley, Governor
April 29, 2003
Mr. Bryan Laney, Environmental Manager
Buckeye Lumberton, Inc.
1000 E. Noir Street
Lumberton, NC 28359
SUBJECT: Compliance Evaluation Inspection
Buckeye Lumberton Inc.
Wastewater Treatment Plant
NPDES Permit No. N,C0005321
Robeson County
Dear Mr. Laney:
William G. Ross, Jr., Secretary
Alan Klimek, P.E., Director
Division of Water Quality
Enclosed is a copy of the Compliance Evaluation Inspection conducted April 24, 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. Bryan Laney, Environmental Manager and Mr. Ronald Radford ,Grade IV ORC were appreciated.
During the inspection a copy of the NPDES Compliance Reminders were reviewed and left with facility staff.
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,
t : 'r2trizo -yi ic1C) Li
Belinda S. Henson
Environmental Chemist
/bsh
Enclosures
cc: Mr. Ronald Radford, ORC, Buckeye Lumberton, Inc.
Fayetteville Regional Office
225 Green Street - Suite 714, Fayetteville, North Carolina 28301-5043
Phone: [phone]/FAX: [phone] \ Internet: www.enr.state.bc.us/ENR
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)
TLansaction Code NPDES yr/mo/day Inspection
1 l_I Ir,t L.J 2 t l 3I N00005321 111 12I 03/04/24 117
Type Inspector Fac Type.
18' tU
19 t 20' 1
U
I I I I I' I I 1 L 1 1 1 1 1 1 166
Remarks
21) III I I I I I III I I I I I I I I I I I I I I I I I I I
Inspection Work Days Facility Self -Monitoring Evaluation Rating B1 QA - ----------------Reserved
72 I ,,r t 73 I I 174 75I I' I I I I 180
67 I 2.5 169 70 Li
t, I 71 t r I LJ
Section B: FacilityData
Name and Location of Facility Inspected (For Industrial Users discharging to POTW, also include
POTW name and NPDES permit Number)
Buckeye Lumberton Incorporated
1000 East Noir Street
Lumberton NC 28359
Entry, Time/Date
08:35 AM ,03/04/24
Permit Effective Date
02/03/01
Exit Time/Date
12:00 PM 03/04/24
Permit Expiration Date
04/07/31
Name(s) of Onsite Representative(s)/Titles(s)/Phone and Fax Number(s)
Ronald Earl Radford/ORC/910-738-3940/
Bryan Laney//910-737-3243/
Bryan Laney//910-737-3243/
Other• Facility Data
Name, Address of Responsible Official/Title/Phone and Fax Number
Contacted
Bryan A Laney,PO Box 1305 Lumberton NC 28359//910-737-3200/
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)
The pulp mill part of the process with Buckeye.will be moving to an existing site in Tennessee. The
closure of the pulp mill will possibly occur by the end of July 2003. The othei process line (cosmetic
cotton balls) will remain at the Lumberton plant with approximately 256,00 gallons of wastewater
generated per day. Mr. Laney discussed during the inspection a few possibilities that could occur: the
remaining wastewater piped to the City of Lumberton or continuing the operation iof the
(cont.)
Name(s) and Signature(s) of Inspector(s) - Agency/Office/Phone and Fax Numbers Date
(� �� i
Belinda S Henson �f FRO WQ//910-468-1541/910-486-0707 _ 2C/ - U ••
Signature of Management Q A Reviewer Agency/Office/Phone and Fax Numbers Date
EPA Form 3560-3 (Rev 9-94) Previous editions are obsolete.

3I
NPDES
NC0005321
11 12
yr/mo/day
03/04/24
117
Inspection Type
18 I, t
(cont.) 1
Section D: Summary of Finding/Comments (Attach additional sheets of narrative and checklists as necessary)
existing wastewater treatment facility on a smaller scale. The domestic wastewater from this facility
continues to be discharged to the City of Lumberton's WWTP.
Three main influent pumps are used with one operational at a time and the other two used as backups. One
pump was not operational at the time of the inspection.
The primary clarifier appeared to be operational. Some foam not excessive was noted on the water surface
of the clarifier. As noted in the last inspection report dated February 25, 2002, areas in the clarifier
appeared to have paint worn from the surfaces and rusty areas were noted. If the WWTP continues
operation and this component is utilized in the treatment of wastewater these items should be maintained.
The aerobic selector is made up of : influent, return activated sludge (RAS), and solids from the
secondary clarifiers. The selector was installed to assist with filamentous bacteria reduction.
The aeration basin has a capacity of 5.5 MG. Eighteen (18) aerators are located in the basin with six
(6) at the head of the basin, which are 75 Horsepower and the remaining being 40 Horsepower. One aerator
was not operational and plans are to repair it in the near future. A new blend of phosphoric acid and
urea are added' to the aeration basin to assist with wastewater treatment. The blend is a ratio of 18%
phosphoric acid and 28% urea. The aeration basin appeared to be operating adequately. The most recent
Mixed Liquor Solids (MLSS) result was 4200 mg/L. Defoamer continues to be added to the basin to reduce
foaming.
Clarifier 01 had a sludge depth of 12 feet with a tank depth of 15 feet. Clarifier #2 had a sludge depth
Of 11 feet with a tank depth of 15 feet. Clarifier #3 had a sludge depth of 4 feet with a tank depth of
10 feet.
THE FACILITY HAS CORRECTED THE FOLLOWING PROBLEMS SINCE THE LAST INSPECTION DATED FEBRUARY 1, 2002: THE
CHANNEL WALLS FOR THE EFFLUENT FROM THE CLARIFIERS WHICH FLOWS TO THE PARSHALL FLUME HAS BEEN HEIGHTENED
TO ELIMINATE EFFLUENT SPLASHING ONTO THE GROUND AND NEW SEALS WERE ADDED TO THE TWO RETURN PUMPS LOCATED
ADJACENT CLARIFIER #1 AND CLARIFIER #2. POTABLE WATER IS USED FOR SEALING AND IT ELIMINATED OIL USAGE
AND POSSIBLE LEAKAGE.
The effluent appeared to be free of solids with a brown color which is representative of this specific
type of wastewater.
The temperature of the effluent composite sampler refrigerator was 3 degrees Celsius. The acceptable
temperature range of samples during storage and for stored sample extracts, is 1.0 - 4.4 degrees Celsius.
Ref: Federal Register, July 1, 1995; 40 CFR 136; Table II.
The effluent Badger Meter Model 2100 Ultrasonic flowmeter is used to report flow on the Discharge
Monitoring Reports (DMRs). The flow meter was calibrated June 21, 2002 by facility instrumentation
staff.
The solids wasted from the system are from the primary and secondary clarifiers. Polymer and a sludge
press dewater the biosolids. The solids go into the belt press at 1 - 1 2 percent and leave the press at
15 - 17 percent. All biosolids are land applied to permitted land. The land application permit #
WQ0002932 permits approximately 1684 acres. Approximately 800 acres are owned by the facility and the
remainder is leased from other farm owners. A holding tank is located at the permitted site that can
hold from 30 - 60 days of sludge.
The facility has a certified laboratory onsite (certification # 525) which analyzes the following NPDES
permit required parameters: pH, Temperature, Dissolved Oxygen, Ammonia, BOD, Total Suspended Solids, and
Conductivity. TBL is the commercial laboratory that is responsible for the analyses of all other NPDES
permit required parameters.

NPDES
31 NO0005321 I11 12I
yr/mo/day
03/04/24
117
Inspection Type
18i
(cont.) 2
Section D: Summary of Finding/Comments (Attach additional sheets of narrative and checklists as necessary)
Laboratory records were reviewed for the months March 2002 and compared to Di,`scharge Monitoring Records
(DMRs). All records reviewed appeared to be adequately reported.
The Backup Operator for this'facility continues to be Kenny Emanuel. He is a, Grade III certified
wastewater operator.
The facility calculates MCAT and F/M ratios to assist with proper treatment of the wastewater as well as
tracking trends with BOD and other parameters. A computer program on Microsoft Excel assist with
wastewater treatment calculations. -
A computer program which allows staff to email a worksheet to the maintenance staff when repairs are
i
needed tracks maintenance. There is not a designated maintenance staff for the WWTP. Maintenance staff
is basically for the facility as a whole.

Regional Field Inspectors Check List for Field Parameters
•
Jame of site to be Inspected: e\Rc..Ke y < kw 0,1 he-r-tort) Date.. 4--
'ield certification # (if applicable): Inspector: t 1; ncc, es, )4,,
cvo
4PDES #: A/C-0 06 g 931 Region: Fcqr•Heoilts
. Circle the parameter or parameters performed at this site.
lesidual Chlorine, Settleable Solids,),
I. Instrumentation:
k. Does the facility have the equipment necessary to analyze field parameters as circ ed above?
1. A pH meter No
2. A Residual Chlorine meter Yes No
3. DO meter No
4. A Cone for settleable solids Yes No
5. A thermometer or meter that measures temperature.
6. CondUctiVity meter
III. Calibration/AnalVsis:
1. Is the pH meter calibrated with a 2 buffers and
checked with a third buffer each day of use? No
2. For Total Residual Chlorine, is a -check standard
analyzed each day of use? Yes
3. Is the air calibration of the DO meter performed
each day of uSe? (!)
4. For Settleable SolidS,' is 1 literof sample ,
settled for 1 hour? Yes
5. Is the temperature measuring device calibrated
annually against a certified thermometer? No
•
6. For Conductivity, is a calibration standard
analyzed each day of use? "s7)
No'
No
No
Nol •
No,
No

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:
IV. Documentation:
1. Is the date andtime that.the sample was collected documented? fir No
No
e
•
Ees
es'
No
No
CYes No
No
e
Yes
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

Section D: SQ@ jy of Findings/Comments
Brief Facility Description:
A 2.5 MGD WWTP consisting of the followiny. treatment units: screening, grit removal. primary
clarification, equalization basin, aerobic selector, aeration basin with nutrient addition : hosphoric
acid 8i, urea blend), final clarification (3), sludge holding tank, and sludge nress.
FACILITY SITE REVIEW
es` No N/A 1. Treatment units properly operated and maintained.
Yes.' N/A 2. Standby power or other equivalent provision provided.
Yes No N/A 3. Adequate alarm system for power or equipment failure available.
4. Sludge disposal procedures appropriate:
Vs.") No N/A a. Disposal of sludge according to regulations
No N/A b. State approval for sludge disposal received.
Tes7° No N/A 5. Sufficient sludge disposed of to maintain treatment process equilibrium.
Yes? No N/A 6. The ORC and Backup Operator are officially designated with
NCDENR/DWQ Training and Certification Unit.
'y`es) No N/A 7. Adequate spare parts and supplies inventory maintained.
l e� No N/A • 8. Plant has general safety structures such as rails around or covers over
tanks, pits, or wells.
es No N/A 9, Plant is generally clean, free from open trash areas.
10. Screening:
Yes No N/A 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.
Yes No N/A
Yes No N/A
Yes No N/A
Grit Removal:
a. Excessive organic content in the grit chamber,
b. Excessive odors
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
12.
O N/A
N/A
(G5 N/A
1113 N/A
No N/A
in? N/A
Vo N/A
Cp' N/A
No N/A
No N/A
No`
No N/A
No N/A
No N/A
No N/A
No N/A
NoN/A
No N/A
Yes Co N/A
Yes CST& N/A
Yes Sb N/A
Yes ad N/A
Yes Via' N/A
Yes No 0
Yes No CR/A7
Yes
Yes
Yes
Yes
No%N
No N/A
No N/A
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
j, Broken sludge scraper.
13. Trickling Filter:.
a. Trickling filter 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.
e.
f.
g.
Uneven or discolored growth
Excessive sloughing of growth
Odor
Clogging of trickling filter's distribution arm orifices
h. Filter flies, worms, or snails.
14. Activated Sludge Basins/Oxidation Ditches:
a. Dead spots
b. Failure of surface aerators c 66='
c. Air rising in clumps
d. Dark foam or bad color
e. Thick billows of white, sudsy foam
f. 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 :ES-0 N/A a. Excessive gas bubbles on surface
Yes N) N/A b. Level overflow weirs
Yes (lo N/A c. Weir blockage
Yes go N/A d. Evidence of short circuiting
Yes to N/A e. Excessive buildup of solids in center well of circular clarifier
Yes cN N/A f. Pin floc in overflow
YesNo N/A g. Effective scum rake
Yes No N/A h. Floating sludge on surface
Yes aA N/A i. Excessive high sludge blanket
Yes (S'o N/A j. Clogged sludge withdrawal ports on secondary clarifier.
17. Filtration:
Yes No 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 No %) a. Sludge buildup in contact chamber
Yes No N/A b. Gas bubbles
Yes No N/A c. Floating scum and/or solids
Ye's 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 19. Ultraviolet radiation disinfection present and in use.
20. Dechlorination:
Yes No CIS 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 No gA
Yes No N/A
Yes No N/A
Yes No N/A
21. Aerobic Digester:
a. Excessive foaming in tank
b. Noxious odor
c. Mechanical aeration failure
d. Clogging of diffusers.
J

Page 4
Yes No
Yes No N/A
Yes No
Yes No
Yes No
Yes No
Yes No
Yes No
�es No
N/A
Yes No N/A
Yes No N/A
Yes NJJ N/A
Yes go N/A
Yes No
Yes No N/A
Yes No N/A
Yes C1St) N/A
Yes CIS N/A
Yes No N/A
22. Anaerobic Digester:
a. Floating cover tilting
b. Gas burner operative
23. Sludge Drying and/or disposal:
a. Poor sludge distribution on drying beds
b. Vegetation in drying beds
c. Dry sludge remaining in drying beds
d. Dry sludge stored on site
e. Filtrate from sludge drying beds returned to front of plant
f. Sludge disposal through county landfill.
g. Sludge land applied.
24. Filter Press:
a. High level of solids in filtrate from filter presses or vacuum filters
b. Thin filter cake caused by poordewatering
c. Sludge buildup on belts and/or rollers of filter press
d. Excessive moisture in belt filter press sludge cake.
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:
5' No N/A a. Proper placement of flow measurement device
Cues) No N/A b. Flow meter calibrated
Yes (SIB) N/A c. Buildup of solids in flume or weir
Yes No N/A d. Broken or cracked flume or weir
Yes No N/A e. Clogged or broken stilling wells
Yes No N/A f. Weir plate edge corroded or damaged
Yes No N/A g. Flow measurement error less than 10%.

Page 5
28.
e No N/A
Yes. No N/A
es� No N/A
Ys7 No N/A
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.
�ii No N/A
Ora No N/A
(fa No N/A
No N/A
. No N/A
s)No N/A
e, No N/A
No N/A
'e) No N/A
Yes No N/A
fees ) No N/A
Yet No N/A
Ye
No N/A
No N/A
s1 No N/A
RECORDKEEPING AND REPORTING
1. Records and reports maintained as required by permit.
2. All required information available, complete, and current.
3. Records maintained for 3 years and all sludge records maintained for 5
years.
4. Analytical results consistent with data reported!on DMRs.
5. Sampling and analyses data adequate and include:
a. Dates, times, and location of sampling
b. Name of individual performing sampling
c. Results of analyses and calibration
d. Dates of analyses
e. Name of person performing analyses.
6. Monitoring records adequate and include:
a. Monitoring charts kept for 3 years
b. Flowmeter calibration records kept for 3 years.
7. The pH meter is calibrated daily with two buffers and checked with a
third buffer and properly documented.
8. Expiration dates of pH buffers adequate.
9. All thermometers used in NPDES permit reporting is calibrated
annually with an NIST certified thermometer or a traceable
thermometer annually and documented.
10. The following NPDES permit required parameters are analyzed on site:
pH, Temperature, Dissolved Oxygen and Chlorine Residual.

Page 6
Yes No /A 11. The NPDES permit required parameter Total Chlorine Residual is
analyzed by approved method.
No N/A 12. BOD incubator temperature maintained at 20 +/- 1 Degrees Celsius
and the temperature maintained in a log for every day of operation.
Yes No �/T A� 13. Fecal coliform incubator maintained at 44.5 +/- 0.2 Degree Celsius and
the temperature maintained in a log for every day of operation.
Yes No N/A
Yes No N/A
Yes No N/A
Yes No N/A
14. Plant records adequate and include:
a. • O & M Manual
b. "As -built" engineering drawings
c. Schedules and dates of equipment maintenance repairs
d. Equipment data cards.
Yes No V/A) 15. Permittee is meeting compliance schedule.
No N/A 16. DMRs complete and include all NPDES permit required parameters.
Yes No N/ ' 17. The facility has a permitted flow greater than 5 MGD and is required
to operate seven days per week 24 hours a day.
es/ No N/A 18. ORC visitation logs available and current.
>No N/A
19. ORC certified at a level equal to or greater than the classification of
the wastewater facility.
i'eNo N/A 20. Backup Operator certified at one level less than the classification of
the wastewater facility or greater.
' No N/A 21. Current copy of the complete NPDES permit on site.
(YejNo N/A 22. Facility description verified as contained in NPDES permit.
es No N/A 23. Facility analyzes process control parameters for example: MLSS,
MCRT, Settleable Solids and others that are applicable.
Yes No
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