DEQ-CFW_00060970

August 30, 2005
Michael Johnson
E I DuPont de Nemours and Company
22828 NC Highway 87 West
Fayetteville NC 283067332
Michael F. Easley, Governor
William G. Ross Jr., Secretary
North Carolina Department of Environment and Natural Resources
SUBJECT: August 16, 2005 Compliance Inspection Inspection
E I DuPont de Nemours and Company
Dupont Fayetteville Works
Permit No: NC0003573
Bladen County
Dear: Mr. Johnson
Alan W. Klimek, P.E. Director
Division of Water Quality
Enclosed please find a copy of the Compliance Inspection Inspection form from the inspection conducted on
August 16, 2005. The Compliance Inspection Inspection was conducted by Mark Brantley of the Fayetteville
Regional Office. The facility was found to be in Compliance with permit NC0003573. The cooperation of Mr.
Robert Geddie, Grade IV ORC, Mr. Ray Beard, back-up ORC, and Mr. Bob Shaul, Superintendent was greatly
appreciated.
Please refer to the enclosed inspection report for additional observations and comments. If you or your staff have
any questions, please call me at.
Sincerely,
Mark Brantley
cc: Robert J Geddie, ORC
Central Files
Fayetteville Files
No ehCarolina
�tura!!y
North Carolina Division of Water Quality/Aquifer Protection Section 225 Green St./ Suite 714 Fayetteville, NC 28301 Phone [phone]
FAX [phone] Internet: h2o.enr.state.nc.us Customer Service 1-877-623-6748
An Equal Opportunity/Affirmative Action Employer— 50% Recycled/10% Post Consumer Paper
DEQ-CFW 00060970

United States Environmental Protection Agency
Form Approved.
EPA Washington, D.C. 20460
OMB No. 2040-0057
Water om line Inspection Report
Approval expires 8-31-98
Section A: National Data System Coding (i.e., PCS)
Transaction Code NPDES yr/mo/day Inspection Type Inspector Fac Type
1 U 2 U 31 NC0003573 I11 121 05/08/16 117 181!1 19 LJ 201J
Remarks
2111111IIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIII66
Inspection Work Days Facility Self -Monitoring Evaluation Rating B1 QA -------------------------Reserved---------------------
67I 169 70 U 71 U 72 U 73 W 74 751 1 1 1 1 1 Li 80
Section B: Facility Data
Name and Location of Facility Inspected (For Industrial Users discharging to POTW, also include
Entry Time/Date
Permit Effective Date
POTW name and NPDES permit Number)
09:30 AM 05/08/16
04/02/01
Dupont Fayetteville Works
Exit Time/Date
Permit Expiration Date
22828 NC Highway 87 West
Fayetteville NC 283067332
03:15 PM 05/08/16
06/10/31
Name(s) of Onsite Representative(s)Mtles(s)/Phone and Fax Number(s)
Other Facility Data
Robert J Geddie/ORC/910-678-1219/
Name, Address of Responsible Official/Title/Phone and Fax Number
Contacted
Michael Johnson,22828 NC Highway 87 West Fayetteville NC No
283067332//910-678-1155/
Section C: Areas Evaluated During Inspection (Check only those areas evaluated)
Permit . Flow Measurement Operations & Maintenance Records/Reports
Self -Monitoring Program N Sludge Handling Disposal Facility Site Review Effluent/Receiving Waters
Laboratory
Section D: Summa 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
Mark Brantley FRO WQ///
/4-'W—
Signature of Management Q ANRtellviieewweer %�l10 Agency/Office/Phone and Fax Numbers Date4 J� 1t
ff 910-486-1541 Ext.727/ J A li V .S
Belinda S Henson ''"" /
EPA Form 3560-3 (Rev 9-94) Previous editions are obsolete.
DEQ-CFW 00060971

8
NPDES yr/mo/day Inspection Type
31 NC0003573 I11 12I 05/08/16 117 1811
(cont.) 1
Section D: Summary of Finding/Comments (Attach additional sheets of narrative and checklists as necessary)
The Dupont facility has several sites that produce wastewaster that is treated on site. All of the
wastewater comes together at the influent station at the wastetreatment system. Wastewater is pumped from this
area to the chemical feed area where ammonia and phosphoric acid can be added if neccessary. From here
wastewater goes to an equalization basin and then to a pre-digestor. Wastewater spends about sixteen hours
in these two units together to allow the wastewater to equalize and allow the microrganisms to start to work.
From the digester the wastewater flows into the aeration basin where the waste is broken down. Water then
enters a "degasifier" unit which allows gas bubbles to escape and not to bind to particles in the water. This
allows better settling in the next treatment unit, the clarifier. Water then flows out of the clarifer through
the flume (this is outfall 001 and where a set of samples are taken) into outfall 002's stream. This is
cooling water from the power house. From here the combined flow goes through a man made stream into the Cape
Fear River. When the MLSS becomes to high, solids are wasted from the clarifier through a DAF unit to a solids
tank. Solids are moved from this tank to a press by an auger. The solids content of the material after the
press is 10-15%. Solids are then dried to remove as much water as possible. The solids are dried to a
powder and are then trucked to a landfill in Sampson County where they are disposed of.
Field parameters that are analyzed on site are pH and temperature. Facility contracts with TBL laboratory in
Lumberton, NC for the remaining NPDES permit required parameters.
During the inspection, some areas were noted on the predigester tank that paint was worm. Maintaining these
areas in the near future could eliminate major repairs in the future. Please continue doing touch up
painting on the weirs of the clarifiers.
It is strongly recommended that the thermomters in the samplers be placed in a beaker of water/oil or that
certified thermometers be purchased and placed in samplers to ensure accurate temperatures. An enclosed
thermometer or a thermomter in a beaker of water will cause the thermometer to resist sudden changes in
temperature (such as opening the sampler door or touching the thermomter). An enclosed thermomter can be
bought from any laboratory supply dealer and are fairly in -expensive. Most of these thermometers come with a
certificate of calibration that has an expiration date.
Discharge monitoring reports for the months of January, March, and May of 2005 were reviewed. The ORC's logbook
and bench sheets for the field parameters were also reviewed. All paperwork was found to be in good order.
A weekly BOD violation and a monthly BOD violation for the month of March was reported on the DMR and a
Notice of violation was issued.
Facility was found to be clean, neat, and overall well maintained.
DEQ-CFW 00060972

Permit: NC0003573 Owner • Facility: Dupont Fayetteville Works
Inspection Date: 08/16/2005 Inspection Type: Compliance Inspection
Permit
the present permit expires in 6 months or less). Has the permittee submitted a new application?
Yes No NA
0 E] 0
NE
■
Is the facility as described in the permit?
■ 0 ❑
O
Are there any special conditions for the permit?
0 ❑ ■
0
is access to the plant site restricted to the general public?
■ 0 C1
1)
Is the inspector granted access to all areas for inspection?
■ D C1
0
Comment:
Yes No NA
NE
Operations & Maintenance
Is the plant generally clean with acceptable housekeeping?
■ 0 0
0
Does the facility analyze process control parameters, for ex: MLSS, MCRT, Settleable Solids, pH, DO, Sludge ,fudge,
■ 0 0
0
and other that are applicable?
Comment: Facility runs MLSS, pH, Dissolved Oxygen, and checks the sludge blankets as process controls.
Yes No NA
NE
Pump S ation - lnfiupnt
Is the pump wet well free of bypass lines or structures?
■ O O
O
■ 0
0
Is the wet well free of excessive grease?
■ O O
0
Are all pumps present?
Cl ■ ❑
0
Are all pumps operable?
Are float controls operable?
■ 0 0
F1
■ 0 C1
0
Is SCADA telemetry available and operational?
Is audible and visual alarm available and operational?
C1 0 C3
■
Comment: Facility is replacing influent pumps with larger pumps.
The influent pumps operate off of a bubbler system instead of a float control.
Yes No NA
NE
Fpualization Basins
■ 11 0
El
Is the basin aerated?
Is the basin free of bypass lines or structures to the natural environment?
■ 0 0
0
Is the basin free of excessive grease?
■ 0 C3
0
■ 0 C3
f-1
Are all pumps present?
■ 0 0
0
Are all pumps operable?
0 1:1 ■
0
Are float controls operable?
Are audible and visual alarms operable?
0 0 11
■
Is basin sizelvolume adequate?
■ 0 0
0
Comment: Pumps are variable speed.
The pumps are leveled controlled instead of float controlled.
Yes No NA
NE
Second2ry Cladfier
Is the clarifier free of black and odorous wastewater?
■ O O
O
Is the site free of excessive buildup of solids in center well of circular clarifier?
■ D O
O
■ O O
O
Are weirs level?
■
Is the site free of weir blockage? -
■ C1 C1
O
Is the site free of evidence of short-circuiting?
■ O ❑
D
Is scum removal adequate?
Is the site free of excessive floating sludge?
■ O O
O
■ O 0
O
Is the drive unit operational?
®0 ❑
Is the return rate acceptable (low turbulence)?
Is the overflow clear of excessive solids/pin floc?
■ 0 0
D
Is the sludge blanket level acceptable? (Approximately'/, of the sidewall depth)
■ 0 11
O
Comment: There was more than normal build up of solids in the center well of the circular clarifier.
Please continue touch up painting of weirs as neccessary to prevent rusting.
Sludge levels were 3.5 feet in both clarifer 1 and 2.
DEQ-CFW 00060973

Permit: NC0003573
Inspection Date: 08/1612005
Pumps -RAS -WAS
Are pumps in place?
Owner - Facility: Dupont Fayetteville Works
Inspection Type: Compliance Inspection
Are pumps operational?
Are there adequate spare parts and supplies on site?
Comment: Return pump # 1 is for clarfrer 1, return pump #3 is for clarFer 2, and return pump # 2 is the back-up pump
which can pump either clarfler.
Aeration Basins
Mode of operation
Type of aeration system
Is the basin free of dead spots?
Are surface aerators and mixers operational?
Are the diffusers operational?
Is the foam the proper color for the treatment process?
Does the foam cover less than 25% of the basin's surface?
Is the DO level acceptable?
Is the DO level acceptable?(1.0 to 3.0 mg/1)
Comment: The aeration basin has coarse air diffusers on the bottom and fine air diffusers at the top.
The biomixer is high maintenance. Some areas are currently not operating 100%.
The Dissolved Oxygen level averages around 3.5 mg/I and it was 4.0 mg/I at the time of the inspection.
The miss was 2900 mg/I on 8-16-05.
Standby Power
Is automatically activated standby power available?
Is the generator tested by interrupting primary power source?
Is the generator tested under load?
Yes No NA NE
N ❑ ❑ ❑
N ❑ ❑ ❑
■ ❑ ❑ ❑
Yes No NA NE
Ext. Air
Was generator tested & operational during the inspection?
Do the generator(s) have adequate capacity to operate the entire wastewater site?
Is there an emergency agreement with a fuel vendor for extended run on back-up power?
Is the generator fuel level monitored?
Comment: The facility has two power feeds coming into the plant. (One from PWC in Fayetteville and the other from
Progress Energy's Plant in Lumberton, NC) If power is completely lost then production stops (and the flow to the waste
treatment system stops to) at the plant. The facility can rent portable blowers to aerate the aeration basin in order to
keep the microorganisms alive.
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 1.0 to 4.4 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: The facility use!ba contract lab, TBL, in Lumberton, NC.
Samples are packed on ice and sent to the contract lab as soon as they are collected.
Flow Measurement - Influent
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:
Flow M .as ,r ment - Effluent
Is flow meter used for reporting?
Diffused
N ❑ ❑ ❑
00130
E ❑ ❑ ❑
E ❑ ❑ ❑
N ❑ ❑ ❑
N ❑ ❑ ❑
0000
■ ■ ■
DEQ-CFW 00060974

Permit: NC0003573 Owner - Facility: Dupont Fayetteville Works
Inspection Date: 08/16/2005 Inspection Type: Compliance Inspection
Flow Mpns urement - Effluent Yes
No NA
❑ ❑
NE
❑
Is flow meter calibrated annually?
❑ ❑
❑
Is the flow meter operational?
(If units are separated) Does the chart recorder match the flow meter?
N ❑ ❑
❑
Comment: The effluent meter is a Sigma 980 and is placed on outfall 001. The flow meter is calibrated every 6 months
by ISI. The last calibration performed was done in August 2005. The meter is not connected to a chart recorder but to
a computer system that can generate graphs and charts on a needed basis.
Yes
No NA
NE
Record Keel
Are records kept and maintained as required by the permit?
❑ ❑
❑
Is all required information readily available, complete and current?
❑ ❑
❑
Are all records maintained for 3 years (lab. reg. required 5 years)?
❑ ❑
❑
Are analytical results consistent with data reported on DMRs?
❑ ❑
❑
Is the chain-of-custody complete?
❑ ❑
❑
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?
❑ ❑
❑
Has the facility submitted its annual compliance report to users and DWQ?
❑ ❑ 0
❑
(if the facility is = or > 5 MGD permitted flow) Do they operate 24/7 with a certified operator on each shift?
❑ ❑ E
❑
Is the ORC visitation log available and current?
❑ ❑
❑
Is the ORC certified at grade equal to or higher than the facility classification?
❑ ❑
❑
Is the backup operator certified at one grade less or greater than the facility classification?
❑ ❑
❑
Is a copy of the current NPDES permit available on site?
❑ ❑
❑
Facility has copy of previous year's Annual Report on file for review?
❑ ❑ E
❑
Comment: Other plant staff are availlabe to monitor plant during off hours. The back up operator in charge is Mr. Ray
Beard and he has a grade II wastewater certification.
Yes
No NA
NE
i=ff[rent Sampling
Is composite sampling flow proportional?
❑ ❑
❑
Is sample collected below all treatment units?
0 ❑ ❑
❑
❑ ❑
❑
Is proper volume collected?
❑ ❑
❑
Is the tubing clean?
Is proper temperature set for sample storage (kept at 1.0 to 4.4 degrees Celsius)?
0 ❑ ❑
❑
Is the facility sampling performed as required by the permit (frequency, sampling type representative)?
❑ ❑
❑
Comment: At the time of inspection the composite sampler was at 4.0 degrees celsius. The Division of Water Quality
suggests that the thermometer be placed in beaker of water or that a certified thermomter be purchased
Y
.c No NA
NE
Upstream / Downstream Sampling
Is the facility sampling performed as required by the permit (frequency, sampling type, and sampling location)?
❑ N ❑
❑
Comment: Permittee is a member of the Cape Fear River Basin Association. The Association handles the
upstream/downstream sampling.
Yes
No NA
NE
So idq. Hnndlina Equipment
N ❑ ❑
❑
Is the equipment operational?
s ❑ ❑
❑
Is the chemical feed equipment operational?
N ❑ ❑
❑
Is storage adequate?
❑ ❑
❑
Is the site free of high level of solids in filtrate from filter presses or vacuum filters?
Is the site free of sludge buildup on belts and/or rollers of filter press?
❑ ❑
❑
DEQ-CFW 00060975

Permit: NC0003573
Inspection Date: 08/16/2005
Owner - Facility: Dupont Fayetteville Works
Inspection Type: Compliance Inspection
Solids Handling Equipment
Is the site free of excessive moisture in belt filter press sludge cake?
The facility has an approved sludge management plan?
Comment: Sludge is dried an hauled to a landfill in Sampson County.
Chemial Feed
Is containment adequate?
Is storage adequate?
Are backup pumps available?
Is the site free of excessive leaking?
Comment:
Fffluent 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:
MM
NEE■ ■ ■
DEQ-CFW 00060976

• al Field Inspectors Check List for Field Parameters
Region
Date:',
19
Name of site to be Insp Inspector:`
Field certification # (if applicable): sive
.Region: ��
NPDES#: ,A/C ovo 3S`73
I. Circle
the arameter or para
erformed at this site.
Residual Chlorine, Settleable Solids op,
DO, Conductivity, Temperature
il. Instrumentation:
merit necessary to analyze field parameters as circled above?
P.�i ! v r -Q 6.
A. Does the facility have the equip. e No
f SCJ `z' 3-31-07
1. A pH meter ff czv� Yes No
7
2. A Residual Chlorine meter No 7 -v%
Yes
3. Do meter
4. A Cone for settleable solids
5. A thermometer or meter that measures temperature.
g, Conductivity meter
Ill. Calibration1Ana
1. is the pH meter calibrated with a 2 bufffer�? d
checked with a third buffer each day of
2. For Total Residual Chlorine, is a check standard
analyzed each day of use?
Is the air calibration of the DO meter performed
3.
each day of use?
4, For Settleable Solids, is 1 liter of sample
settled for 1 hour?
5. is the temperature measuring device calibrated
annually against a certified thermometer?_.
6. For Conductivity, is a calibration standard
analyzed each day of use?
Yes No
Yes No
Yes No
es No
Yes No
Yes No
Yes No
Yes No
Yes No
DEQ-CFW 00060977