NC0005321_Inspection_20020225

AVA.
NCDENR
North Carolina Department of Environment and Natural Resources
Michael F. Easley, Governor
Febniary 25, 2002
Mr. Brian 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. NC0005321
Robeson County
Dear Mr. Laney:
William G. Ross Jr., Secretary
Gregory J. Thorpe, Ph.D.
Acting Director
Division of Water Quality
Enclosed is a copy of the Compliance Evaluation Inspection conducted February 1, 2002.
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. Brian Laney, Environmental Manager and Mr. Ronald Radford ,Grade IV ORC were appreciated.
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,
Belinda S. Henson
Environmental Chemist
/bsh
Enclosures
cc: Mr. Ronald Radford, ORC, Buckeye Lumberton, Inc.
225 GREEN STREET - SUITE 714 / SYSTEL BUILDING / FAYETTEVILLE, NC 28301-5043
PHONE [phone] FAX [phone] \VWW.ENR.STATE.NC.1.1S/ENR/
AN EQUAL OPPORTUNITY / AFFIRMATIVE ACTION EMPLOYER - 50% RECYCLED/10% POST CONSUMER PAPER
DENR TOLL FREE HOTLINE: [phone]

NPDES COMPLIANCE INSPECTION REPORT
North Carolina Division of Water Quality
Fayetteville Regional Office
Section A. National Data System Coding
Transaction Code: N NPDES NO. NC0005321 Date: 020201 Inspection Type: C
Inspector: S Facility Type: 2 Reserved:
Facility Evaluation Rating: 4 BI: N QA: N Reserved:
Section B: Facility Data
Name and Location of Facility Inspected:
Buckeye Lumberton Inc. WWTP
Entry Time/Date: 9:45 am/020201 Permit Effective Date: 000301
Exit Time/Date: 1:15pm/020201 Permit Expiration Date: 040731
Name(s), Title(s) of On -Site Representative(s):
Brian Laney - `Environmental Manager"
Ronald Radford (Certified Grade IV Operator) - "ORC"
Phone Number(s): [phone]
Name, Title and Address of Responsible Official
Mr. Brian Laney, Environmental Manager
Buckeye Lumberton, Inc.
1000 E. Noir Street
Lumberton, NC 28359
Contacted: yes
Section C: Areas Evaluated During Inspection
(S = Satisfactory, M = Marginal, U = Unsatisfactory, N = Not Evaluated, N/A = Not Applicable)
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Laney
Page 3
February 25, 2002
Section D: Summary of Findings/Comments:
1. A draft permit dated May 30, 2001 has been submitted to the facility which modified the NPDES permit
to increase the hydraulic design capacity from 1.8 MGD to 2.5 MGD as ;per, their request. All other
permit conditions will remain the same. The fmal permit is presently under review.
2. The domestic wastewater from this facility is discharged to the City of Lumberton's wastewater
treatment plant.
3. Carbon dioxide is added to the influent to neutralize pH when necessary. Carbon Dioxide adjusts a pH
of 11.0 in the influent to.10.0 - 10.5. • 1
4. Three main pumps are used to pump the influent into the plant. One pump is used at any given time
with the other pumps used as backups.
5. The primary clarifier appeared to be operational with no floatable foam noted on the water surface.
Areas in the clarifier appeared to have paint wom from the surfaces and rusty areas were noted. These
areas should be repaired in the near future to eliminate further expense to the facility.
6. The aerobic selector is made up of: influent, return activated shidge (RAS), and solids from the
secondary clarifiers. The selector was installed to assist with filamentous bacteria reduction.
7. 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.
Ammonia and Phosphoric Acid is added to the aeration basin at a rate of 20 gallons/day to assist with
treatment of the wastewater. The aeration basin appeared to be operating adequately. The most recent
Mixed Liquor Suspended Solids (MLSS) result was 5900 mg/L. The MISS is analyzed daily. The
optimum range for this facility is 5500-6000 mg/L as per Mr. Laney' Defamer is added to the MLSS
to assist with foam reduction.
8. Clarifier #1 had a sludge depth of 10 feet with a tank depth of 15 feet. Clarifier #2 had a sludge depth
of 10 feet with a tank depth of 15 feet. Clarifier #3 had a sludge depth�of 4 ''/2 feet with a tank depth of
10 feet.
9. Effluent from the clarifiers was noted on the ground beside the channel 'which flows to the effluent
parshall flume. In this area the effluent is aerated before it is discharged to+tLumber River. Plexy glass
had been added to different areas of the top of the channel to assist wit1i this problem but it has not
eliminated it.

Laney
Page 4
February 25, 2002
10. The two return pumps located adjacent Clarifier # 1 and #2 were leaking oil. There is containment
around this area with a dram which flows to the head of plant. The pumps should be repaired
immediately to eliminate oil leakage. This was noted in the last inspection report dated March
13 2001
11. The effluent appeared to be free of solids with a brown color which is representative of this specific type
of wastewater.
12. The effluent composite sampler 3710 Isco is flow proportional by constant volume/variable time. The
temperature of the effluent composite sampler refrigerator was 2.7 degrees Celsius. The acceptable
temperature range of samples during storage and for stored sample extracts, is 1.0 - 4.4 degrees Celsius.
13. The effluent outfall was easily accessible. The effluent discharges directly into the middle of the stream
of Lumber River.
14. The effluent Badger Meter Model 2100 Ultrasonic flowmeter is used to report flow on the Discharge
Monitoring Reports (DMRs). The flow meter was calibrated August 18, 2001 by facility
instrumentation staff.
15. The solids wasted from the system are from the primary and secondary clarifiers. For the month of
December 2001, approximately 8000 -14000 pounds per day was wasted. The biosolids are dewatered
by polymer and a sludge press. The solids go into the belt press at 1 - 1 Y2 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 which
can hold from 30 - 60 days of sludge.
16. The facility has a certified laboratory on site that analyzes the following NPDES permit required
parameters: pH, Temperature, Dissolved Oxygen, Ammonia, BOD, Total Suspended Solids, Total
Chlorine Residual and Conductivity. All other required parameters are contracted with the commercial
laboratory "TBL".
17. During a tour of the certified laboratory on site, pH buffers' expiration dates were reviewed and the
following findings were noted:
10.00 - expires February 2002
7.00 - expires April 2002
4.00 - expires November 2003.
18. Laboratory records were reviewed for the month April 2001 and compared to Discharge Monitoring
Records (DMRs). All records reviewed appeared to be adequately reported.
19. The "Backup Operator" for this facility is Kenny Emanuel. He is a Grade III certified wastewater
operator.

Laney
Page 5
February 25, 2002
20. The facility calculates MCRT 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.
21. Maintenance is tracked by a computer program which allows staff to email a worksheet to the
maintenance staff when repairs are needed. There is not a designated maintenance staff for the WWTP.
Maintenance staff is basically for the facility as a whole.
PLEASE RESPOND IN WRITING TO ITEMS #9 AND #10 BY MARCH 31,
2002.
Name and Signature of Inspector
Belinda S. Henson
Name and Signature of Reviewer
Paul E. Rawls
Action Taken
Agency/Office/Telephone Date
DENR/Fayetteville/[phone] 2. - 25--o
Agency/Office/Telephone Date
DENR/Fayetteville/(9 10)4 8 6- 15 4 1
Regulatory Office Use Only
Compliance Status
Noncompliance
_Compliance
y
Date

•
Section D: Summary of Findings/Comments
Brief Facility Description:
1.8 MGD WWTP consisting of screening, grit removal, primary clarification, equalization basin,
aerobic selector, aeration basin with nutrient addition and methanol feed. final clarification, sludge
holding tank and sludge press.
FACILITY SITE REVIEW
(Vei`. No N/A 1 Treatment units properly operated and maintained.
Yes of 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:
Yesj No N/A a. Disposal of sludge according to regulations
iYes)No N/A b. State approval for sludge disposal received.
es`` No N/A 5. Sufficient sludge disposed of to maintain treatment process equilibrium.
�es No N/A 6. The ORC and Backup Operator are officially designated with
NCDENR/DWQ Training and Certification Unit.
No N/A 7. Adequate spare parts and supplies inventory maintained.
',No N/A 8. Plant has general safety structures such as rails around or covers over
tanks, pits, or wells.
(Yes f No N/A 9. Plant is generally clean, free from open trash areas.
10. Screening:
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. Grit Removal:
Yes No N/A a. Excessive organic content in the grit chamber
Yes No N/A b. Excessive odors
Yes No N/A c. Grit properly disposed of.

r
Page 2
12. Primary clarifier:
Yes Ca - N/A a. Excessive gas bubbles..
Yes N/A b. Black and odorous wastewater
Yes I'' N/A . c. Poor suspended solids removed
Yes N/A d. Excessive buildup of solids in center well of circular clarifier
Yes N/A . e. Weirs level
• Yes aSro • N/A f Weir blockage
Yes to N/A g. Evidence of short circuiting
Yes (MN/A h. Lack of adequate scum removal
- Yes 63 N/A i. Excessive floating sludge
Yes j N/A j. Broken sludge scraper.
Yes No
Yes No
Yes No
Yes No
Yes No
Yes No
Yes No
Yes No
NSA
N/A
NIA
N/A
N/A
NIA
13. Trickling Filter:
a. Trickling filter ponding(indicating clogged media) •
b. Leak at center column of tricklingfilter's distribution arms
c. Uneven distribution .of flow on trickling filter surface
d. Uneven or discolored growth
e. Excessive sloughing of growth
f. Odor
g: Clogging of trickling filter's distribution arm orifices
h. Filter :flies, worms, or snails.
14:. Activated Sludge Basins/Oxidation.Ditches:
Yes N/A a. Dead spots
Yes N/A b. Failure of surface aerators
Yes E9 N/A c. Air rising in clumps
Yes N/A d. Dark foam or bad color .
Yes N/A e. Thick billows of white, sudsy foam
Yes No NCR £ Air rising unevenly
Yes No A g. Excessive air leaks in compressed air piing.
15. Stabilization Pbnds/Lagoont:
Yes No OR a. Excessive weeds including duckweed in, stabilization ponds
Yes No N/A ' . b. Dead fish or aquatic organisms
• Yes No N/A c. Buildup of solids around influent pipe 1
Yes No N/A d. Excessive scum on surface.

Page 3 .
Yes N/A
No N/A
Yes OD N/A
Yes N/A
16. Secondary Clarifier: .
a. Excessive gas bubbles on surface
b. Level overflow weirs
c. Weir blockage • -
d. _Evidence of short circuiting
Yes ( N/A e. Excessive buildup of solids in center well of circular clarifier
Yes i` N/A f Pin floc in overflow .
No N/A g. Effective scum rake
Yes N/A h. Floating sludge on surface •
Yes No N/A i. Excessive high sludge blanket
Yes ( N/A j. Clogged sludge withdrawal ports on secondary clarifier.
17. Filtration:
Yes No /f 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 N 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. N.IOSH-approved 30 minute air pack
Yes No N/A f. All standing chlorine cylinders chained in place
Yes No N/A g. Ali personnel trained in the use of chlorine
Yes No N/A h. Proper chlorine feed, storage, and reserve supply.
Yes . No 1 T A) 19. Ultraviolet radiation disinfection present and in use.
20. Dechlorination:
Yes No 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 N%
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.

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 No 71,A. 'a. Poor sludge distribution on drying beds
Yes No b. Vegetation in drying beds
Yes No 1/ c. Dry sludge remaining in drying beds
Yes No r d. Dry sludge stored on site
.Yes No N e. Filtrate from sludge drying beds returned
Yes No, N/ • f Sludge disposal through county landfill.
No NIA- g. Sludge land applied.
to front of plant
24. Filter Press:
Yes N/A a. High level of solids in filtrate from filter -presses or vacuum filters
Yes +jrti N/A b. Thin filter cake caused by poor dewateru g
Yes N/A c. Sludge buildup on belts and/or rollers offlter press
Yes ei N/A d. Excessive moisture in belt filter press sludge cake.
Yes No (N%A
Yes No N/A
Yes . No N/A
25. Polishing Ponds or Tanks:
a. Objectionable odor, excessive foani, floating solids, or oil sheens on
water surface
b. Solids or scum accumulations in tank or at side of pod
c. Evidence of bypassed polishing ponds or tanks because of low
• capacity.
26. Plant Effluent:
Yes i NIA a. Excessive suspended solids, turbidity, foam, grease, scurn, color, and
other macroscopic particulate matter present
• Yes o N/A b. Potential toxicity (dead fish, dead plant at' discharge)
e No N/A , c. Outfall discharge line easily accessible.
es) No N/A
No N/A
Yes ep N/A
Yes 0 N/A
Yes No <�?A
Yes No N
Yes No N/A
N
27. Flow Measurement:
a. Proper placement of flow measurement dzvice
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%.

t
Page 5
No N/A
02) No N/A
No N/
es) 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.
Ce_sD No N/A
No N/A
No N/A
RECORDKEEPENTG AND REPORT1I G
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.
(Yet No N/A 4. Analytical results consistent with data reported on DMR s.
No NIA
No N/A
No N/A
No N/A
No N/A
No N/A
No N/A
No N/A
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.
Ye No N/A 8. Expiration dates of pH buffers adequate.
es No N/A
9. All thermometers used in NPDES permit reporting is calibrated
annually with an NET 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.
-J

Page 6
No N/A 11. The NPDES permit required paraineter Total Chlorine Residual is
analyzed by approved method.
CO 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 13. Fecal coliforrn incubator maintained at 44,5 /- ,0.2 Degree Celsius and
the temperature maintained in a log for every day of operation.
• 14. Plant records adequate. and include:
Yes No N/A a. 0 8; M Manual
Yes No N/A b. "As -built" engineering drawings
es No N/A c. Schedules' and dates of equipment maip tenance repairs
• Yes No i"il•' d. Equipment data cards.
Yes No
15. Permittee is meeting compliance schedule.
No N/A16. DMRs complete and include all N'PDES permit ;required parameters.
Yes No N/A 17. The facilityhas a permitted flow greater than 5 MGD and is required
to operate seven days per week 24 hoursa day. •
No N/A 18. ORC visitation logs available and current.
Yes No N/A 19. ORC certified at a level equal to or greater than the classification of
the wastewater facility.
No N/A 20. Backup Operator certified at one level lees than the classification of
the wastewater facility or greater.
Ye' No N/A 21. Current copy of the complete NPDES permit on site.
No N/A '22. Facility description verified as contained in NPDES permit.
Y a No N/A 23. Facility analyzes process control parameters for example: NE,SS,
MCRT, Settleable Solids and others that are applicable.
Yes No 24. Industrial Waste Surveys (INS) sent to.all possible Significant .
Industrial Users (SIUs) within the last five years (especially new
industries).
Revised 7/16/01
by Belinda Henson

BUCKEYE
1000 EAST NOIR ST., P.O. BOX 1305
LUMBERTON, NORTH CAROLINA 28359
TEL [phone] FAX [phone]
Belinda Henson
North Carolina Department of Environment and Natural Resources
Division of Water Quality
Fayetteville Regional Office
225 Green Street
Suite 714 — Systel Building
Fayetteville, NC 28301-5043
Subject: NPDES Compliance Inspection Report
Belinda:
This letter will serve as a response to the NPDES Compliance Inspection Report
for the inspection of the Buckeye Lumberton Incorporated wastewater treatment plant
performed February 1, 2002.
Your first finding was in regards to the aerated effluent channel that flows to the
Lumber River. At the time of the inspection, there were a couple of small puddles of
treated effluent on the ground beside the channel. This problem began last spring when
we replaced the blower that provides the air stream to some diffusers located in this
channel. The diffusers are there for when we need to increase the, dissolved oxygen in
the final effluent. The new blower has an increased output, and when combined with an
increased flow through the channel, causes effluent to bubble over the side of the effluent
trough. We had originally placed small lexan sheets over specific areas of the channel to
prevent splashout, but this did not eliminate the problem. Temporarily, we intend to
attach lexan sheets to the inside of the concrete wall on both sides to effectively raise the
wall approximately one (1) foot. Longer term, we intend to raise the concrete formed
wall of the effluent trough by approximately the same height. Additionally, we are
evaluating the placement of additional diffuser stones in the trough to spread out the
airflow to the channel. I have attached the work order that has been submitted to put up
the sheets of Texan in the short term, and will be soliciting quotes for permanently raising
this effluent trough wall. I am confident this will fix the problem.
At the time of the inspection, the two return pumps (Fairbanks Morris pumps)
located adjacent to the #1 secondary clarifier at the South end of the basin were also
BUCKEYE LUMBERTON INC.

leaking. These pumps are used to pump effluent from the aeration basin to the #3
secondary clarifier located at the North end of the basin. Again, the pumps are in
secondary containment, and are functioning properly, however we do recognize this as a
housekeeping issue. We have decided to put these pumps on a monthly preventive
maintenance schedule so that we can tighten the packing and seals on both of these
pumps at least monthly. I have attached the work order request for this task. While we
are evaluating other options such as running a seal water line to this location, we have
already rebuilt the #1 pump and are in the process of rebuilding the #2 pump. The
maintenance depadinent replaced the bearing, seal, and sleeve on !the #1 pump as well as
repacked this pump. We had to order some items for the #2 pump, so an overhaul of this
pump is scheduled for when the replacement parts come in. I will follow-up with you by
e-mail once this has been completed. The environmental department will also begin
washing down this area weekly and noting any problems in the form of work orders that
will be submitted to maintenance on a timely basis.
If you have any questions, comments, or would like any additional information,
please give me a call at (910) 737 — 3243.
Thanks,
Bryan A. Laney
Environmental Manager

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Description: Please remove the grating and attach lexan sheets to the inside
of the exisitng concrete wall, extending approximately one foot above the
current top of the effluent channel. Please place these sheets from the
a discharge of #1 clarifier to approximately the white PVC airline. This will
a effectively raise the effluent trough wall by about one foot and prevent
:splash out due to the blower. This is a temporary solution. Long term plan
:to raise the concrete wall about one-two feet. Any questions, see me.
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:Description: Please put the Fairbank Morris pumps at the South end of the
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A When Completed Please E-Mail this
seals tightened on these pumps monthly to prevent
UNCONTROLLED DOCUMENT
Form to: Johnny Hunt & Sandra Carr