NC0005762_Inspection_20130711

ATA
NCDENR
North Carolina Department of Environment and Natural Resources
Division of Water Quality
Pat McCrory Thomas A. Reeder John E. Skvarla, III
Governor Acting Director Secretary
July 11, 2013
Ronald Locklear, ORC
WestPoint Home, Inc.
19320 Airbase Road
Wagram, NC 28396
SUBJECT: Compliance Evaluation Inspection
WestPoint Home, Inc.
NPDES Permit No. NC0005762
Scotland County
Dear Mr. Locklear,
Enclosed you will find a copy of the Compliance Evaluation Inspection report for the
June 21, 2013 inspection. All observations are in the enclosed EPA Water Compliance
Inspection Report and the Regional Field Inspectors Check List for Field Parameters. On the day
of this CEI, this facility was found to be in compliance with the NPDES permit NC0005762. I
appreciated the time and professional courtesy that was extended to me during the inspection by
you, Fred Locklear (Back -Up ORC), and Donovan Dennis (WWTP operator). If you have any
questions or comments concerning this report, please feel free to contact me at [phone].
Sincerely,
Dale Lopez
Environmental Specials
Enclosures: EPA Water Compliance Inspection Report
Regional Field Inspectors Check List for Field Parameters
cc: L.E. Lanier, PE, Director, WestPoint Home — Wagram Facility
225 Green Street— Suite 714 — Fayetteville, North Carolina 28301-5043
Phone: [phone] FAX: [phone] \ Customer Service 1-877-623-6748
Internet: www.ncwaterauality.orq
An Equal Opportunity 1 Affirmative Action Employer
NorthCarolina
Naturally

United States Environmental Protection Agency
E %-'� ^ Washington, D.C. 20460
Water C(�mpJi nC'P. Inc p r'tinn Report•Approval
Form Approved.,
OMB No. 2040-0057
expires 8-31 e98
Section A: National Data System _Coding (i e PCs) - •
Transaction Code NPDES yr/mo/day - inspection
1 1 2 11 3I 111 12. 17
N 5 NC0005762 1 13/06/21, • • 1
Type _ Inspector . . Fac Type
.: .;
18I C 1 ; 191 I• 20
•
1 1 1:1 1 1. -1' 1 1: 1 1 1 1 1 1 166
• Remarks
211 1 1 1 1 1 1 1 1 1 I 1 1 1 1 1 1 1 1 1 1 1 1-1' 1 .1 1 1 1 1
Inspection Work Days Facility Self -Monitoring Evaluation Rating .•..B1- • _, `..:_'•,QA •;. `., ; _------Reserved=------
671 2.0 1 69 701 31 711 '1 72, 1 ;. `. 73I.. 1:. 174 :..- 761 1: 1 . 1 ' 1 •. 1 1 1 80
Section B:: Facility Data
Name and Location of Facility Inspected (For Industrial Users discharging to POTW, aise:include -
POTW name and NPDES permit Number)
Wagram plant
NCSR 1407
Wagram NC 28396
. Entry:Time/Date
10 30 AM ' 13%06/21 _
Permit Effective Date
11/02/01
Exit Time/Date .-
03:00 PM : 13/06/21
Permit Expiration Date
14/07/31
Name(s) of Onsite Representative(s)/Titles(s)/Phone and Fax Number(s)
///
Ronald Gene Locklear/ORC/910-369-4392/
Other Facility Data
'
Name, Address of Responsible Official/Title/Phone and Fax Number _ • •
Contacted
Donald Locklear,PO Box 338 Wagram NC 28396//910-369-4392/9103694399 No
Section C: Areas Evaluated During Inspection (Check only those areas evaluated)
Permit Flow Measurement • Operations & Maintenance Records/Reports
Self -Monitoring Program Facility Site Review Multimedia • Laboratory
Section D: Summary of Finding/Comments (Attach additional sheets of narrative and checklists as necessary)
(See attachment summary) .
Name(s) an. Signature(s) of Inspector(s) Agency/Office/Phone and Fax Numbers Date
Dale Lopez FRO WQ//910-433-3300 Ext.712/ e 17/ Vy
610
Signature f Management Reviewer Agency/Office/Phone and Fax Numbers Date
`7// a i 3
A c4,414--19,0
EPA Form 3560-3 (Rev 9-94) Previous editions are obsolete.
Page # 1

NPDES yr/mo/day Inspection Type
31 NC0005762 111 121 13/06/21 117 181
CI
(cont.) Z
Section D: Summary of Finding/Comments (Attach additional sheets of narrative and checklists as necessary)
On the day of this CEI, this facility was found to be in compliance with the NPDES permit NC0005762. I
appreciated the time and professional courtesy that was extended to me during the inspection by you, Fred
Locklear (Back -Up ORC), and Donovan Dennis (WWTP operator). If you have any questions or comments
concerning this report, please feel free to contact me at [phone].
There were 60 to 80 mg/L of MLSS in the aeration basin. Both screw pumps were operational, one was
on-line during the time of this CEI. Corrosion was observed on the screw pumps. All influent flow was
going through the manual bar screen. The mechanical bar screen was down due to a shaft and bearings
that needed replacement; the parts were ordered. In the future, the ORC intends to have the mechanical
bar screen up and running again. The 15-feet deep clarifier solids blanket was approximately 0.5 feet at
the time of this CEI. The other two clarifiers were off-line, probably out -of -service, and not in good repair.
The defoamer pump was operational, but defoamer was only occasionally used. The Effluent flowmeter
was calibrated 05/02/2013 by Mark Mills, of Carolina Technical Services. The Effluent Composite
refrigerator was measured at 2 ° C. No flow was observed and no sample was collected on the day of this
CEI. The aerators were rotated in pairs every day. The two mixers were operated continuously. The RAS
and WAS pumps were operational. There was no standby electrical power. The influent flow meter was
also calibrated (no adjustment was noted by the technician during the last calibration). Because January
25, 2013 was the last day of operation for Gullistan Carpet, the only flow to the WWTP on the day of this
Compliance Evaluation Inspection was from the domestic flow of Gullistan Distribution. This flow was
combined with the occasional flow from the water treatment plant. There was no Effluent flow on the day of
the CEI, nor on the day before this CEI. The flow paced 24-hour Effluent sampler sampled 200 mL with
every 5,000 gallons of Effluent flow. The 7 pH buffer millivolt reading was -11.7 mV.
On July 11, 2013, the FRO was notified that Gullistan Distribution would be closing between September 1st
to 14th .
Page # 2

Permit: NC0005762 Owner - Facility: Wagram plant
Inspection Date: 06/21/2013 Inspection Type: Compliance Evaluation
Operations & Maintenance Yes No, NA NE
Is the plant generally clean with acceptable housekeeping?
■ nnn
Does the facility analyze process control parameters, for ex: MLSS, MCRT, Settleable Solids, pH, DO, Sludge ■
Judge, and other that are applicable?
Comment:
Permit
(If the present permit expires in 6 months or less). Has the permittee submitted a new application?
Is the facility as described in the permit?
# Are there any special conditions for the permit?
Is access to the plant site restricted to the general public? -
Is the inspector granted access to all areas for inspection?
Comment:
Record Keeping
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?
(If the facility is = or > 5 MGD permitted flow) Do they operate 24/7 with a certified operator on each shift?
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?
nnn
Yes No NA NE
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Yes No NA NE
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Page # 3

Permit: NC0005762 Owner - Facility: Wagram plant
Inspection Date: 06/21/2013 Inspection Type: Compliance Evaluation
Record Keeping
Facility has copy of previous year's Annual Report on file for review?
Comment:
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:
Pump Station - Influent Yes No NA NE
Is the pump wet well free of bypass lines or structures? ■ n n n
Is the wet well free of excessive grease? ■ n n n
Are all pumps present? ■ n n n
Are all pumps operable? ■ n n n
Are float controls operable? • n n n
Is SCADA telemetry available and operational? n n n ■
Is audible and visual alarm available and operational? nnn ■
Comment:
Yes No NA NE
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Yes No NA NE
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Bar Screens Yes No NA NE
Type of bar screen
a.Manual ■
b.Mechanical ■
Are the bars adequately screening debris? ■ n n n
Is the screen free of excessive debris? ■ n ❑ El
Is disposal of screening in compliance? ■ n ❑ n
Is the unit in good condition? n n ■ n
Comment: The mechanical bar screen was down due to a shaft and bearings that
needed replacing. The parts were on order..
Secondary Clarifier Yes No NA NE
Is the clarifier free of black and odorous wastewater? ■ ❑ n n
Is the site free of excessive buildup of solids in center well of circular clarifier? ■ n n n
Page # 4

Permit: NC0005762 Owner - Facility: Wagram plant
Inspection Date: 06/21/2013 Inspection Type: Compliance Evaluation.
Secondary Clarifier Yes No NA NE
Are weirs level? ■ n n n
Is the site free of weir blockage? ■ . n n n
Is the site free of evidence of short-circuiting? ■ n n n
Is scum removal adequate? ■ n n n
Is the site free of excessive floating sludge? ■ n n n
Is the drive unit operational? ■ n n n
Is the return rate acceptable (low turbulence)? ■ n n ❑
Is the overflow clear of excessive solids/pin floc? ■ n n n
Is the sludge blanket level acceptable? (Approximately % of the sidewall depth) ■ n n n
Comment: The 15-feet deep clarifier solids blanket was approximately 0.5 feet at the
time of this CEI. The other two clarifiers were off-line and not in good repair.
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 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:
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 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 n ■ n
Incubator (BOD) set to 20.0 degrees Celsius +/- 1.0 degrees? n n ■ n
Comment:
Page # 5

Permit: NC0005762 Owner - Facility: Wagram plant
Inspection Date: 06/21/2013 Inspection Type: Compliance Evaluation
Equalization Basins
Is the basin aerated?
Is the basin free of bypass lines or structures to the natural environment?
Is the basin free of excessive grease?
Are all pumps present?
Are all pumps operable?
Are float controls operable?
Are audible and visual alarms operable?
# Is basin size/volume adequate?
Comment:
Effluent Sampling
Is composite sampling flow proportional?
Is sample collected below all treatment units?
Is proper volume collected?
Is the tubing clean?
# Is proper temperature set for sample storage (kept at less than or equal to 6.0 degrees Celsius)?
Is the facility sampling performed as required by the permit (frequency, sampling type representative)?
Comment: 200 mL of Effluent was sampled by the 24-hour flow proportional sampler
for every 5,000 gallons of Effluent flow.
Yes No NA NE
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W HEW
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Yes No NA NE
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Page # 6

Regional Inspectors' Checklist for Field Parameters
Name: West Point Home, Inc.
Regional.Plant Inspector: Dale Lopez
,
NPDES #: NC0005762
Regibri6I InSpector Contact #: (910) 43)-Facility
12
Field Lab Certification #: 156
Region: Fayetteville
Lab Contact: Fred Locklear
Date: 06/21/2013
I. Check the parameter(s) performed at this site for reporting purposes.
® Total Residual Chlorine (TRC) ® Temperature (TEMP) ® Specific Conductivity (SC)
® pH ® Dissolved Oxygen (DO) ❑ Settleable Residue (SETT)
II.
General Laborato (note an
ry
y
exceptions in section XI)
Are instruments, meters, probes, photometric cells, etc. maintained in good condition?
Are standards, reagents and consumables used within manufacturer expiration dates?
[TRC gel standard is exempt.]
ZYes El No
Yes ❑ No
Are the -following items _Ocumenwhere appUcable)
b Y:
_
1,
Item P ... ':° _ ... -
'TRC
pH '
TEMP
fD- ,
;' G _ '
SETT
Date of sample collection*
J
J
J
J
Ni
Time of sample collection*
Ni
J
J
J
J
Sample collector's initials or signature
J
J
J
J
J
Date of sample analysis*
J •"
J
J
J
J
Time of sample analysis*
J
J
J
J
J
Analyst initials or signature
J
J.
J
Ni
J
Sample location
J
J
J
J
J
*Date and time of sample collection and analysis may be the same for in situ or on -site measurements.
IIIr,. uTotat _. __ _al;Chlorir a
hx
Total Residual Chlorine meter make and model:
HACH DR 4000
Is a check standard analyzed each day of use? (Circle one: gel or liquid standard)
►1 Yes ❑ No
What is the assigned/observed value of the daily check standard?
100 & 200.ig/L
Is a 5-point calibration verification performed? Note date of last verification:
►1 Yes E No
Alternatively, does the lab construct a linear regression, using 5 standards, to calculate
results? Note date of last calibration curve constructed:
❑ Yes /1 No
True values: ►1 pg/L ❑ mg/L 20 50 100 200 400
Obtained values: /1 pg/L ❑ mg/L 24 58 108 214 429
What program are samples analyzed on?
Program 1490
Are results reported in proper units? Check one: ►1 pg/L ❑ mg/L
/1 Yes ❑ No
Are results reported between the facility's permit limit and the compliance limit of 50 pg/L?
If value is less than the low standard, report as "<x", where x=low standard conc.
/1 Yes ❑ No
Are samples analyzed within 15 minutes of collection?
/1 Yes ❑ No
IVF pH = = =
pH meter make and model:
Orion Model 420A
Is the pH meter calibrated with at least 2 buffers per mfg's instructions each day of use?
Note buffers used:
// Yes ❑ No
Is the pH meter calibration checked with an additional buffer each day of use? Note check
buffer used:
/1 Yes ❑ No
Does the check buffer read within ±0.1 S.U. of the known value?
4 Yes ❑ No
Are the following items documented:
Meter calibration?
0 Yes ❑ No
Check buffer reading?
i1 Yes ❑ No
Are samples analyzed within 15 minutes of collection?
// Yes ❑ No
Are sample results reported to 0.1 pH units?
// Yes ❑ No

ate,.. _
- :.. `i.. Temperature -� i `kt't`k ti: �.... A .. z.^'fit ` E`er }` y .....
�... ... __ _ �.. :.e F � tom.. _.�. F1r_. . _� u .: riC .. .i.ia{:..
7i_ ..t ..�._ -.
What instrument(s) is used to measure temperature? Check all that apply:
❑ DO meter ❑ Conductivity meter ❑ Digital thermometer Glass thermometer
pH meter
Is the instrument/thermometer calibration checked at least annually against a NIST
traceable or NIST certified thermometer?
/1 Yes ❑ No
01/18/2013
Are temperature corrections (even if zero) posted on the instrument/thermometer?
❑
Yes
I1 No
Are samples measured in situ or on -site? [REQUIRED - there is no holding time for
temperature]
/1
Yes ❑ No
Are sample results reported in degrees C?
//
Yes ❑
No
V1 F _. DisSOIved Oxygen. , _ ___- .. If:t• T },7, , _ '- :`'..__"`
Y x i
DO meter make and model:
HACH
HQ30d
Is the air calibration of the DO meter performed each day of use?
/1
Yes ❑ No
Are the following items documented:
Meter calibration?
/1
Yes ❑ No
Are samples analyzed within 15 minutes of collection?
//
Yes ❑ No
Are results reported in mg/L?
/1
Yes ❑ No
�Vit
-7. Conductnri fi r _ _- - - ,
Conductivity meter make and model:
Orion
Model 120
Is the meter calibrated daily according to the manufacturer's instructions? Note standard
used (this is generally a one -point calibration):
//
Yes ❑ No
Is a daily check standard analyzed? Note value: 9.37 pS, 994 pS, and 9982 pS
0
Yes ❑ No
Are the following items documented:
Meter calibration?
/1
Yes ❑ No
Are samples analyzed within 28 days of collection?
1/
Yes ❑ No
Are results reported in pmhos/cm (some meters display equivalent pS/cm units)?
/1
Yes ❑
No
Vill $ettieai [e Residue F ''' ,,
o
Does the laboratory have an Imhoff Cone in good condition?
❑ Yes ❑
No
Is the sample settled for 1 hour? 0
❑ Yes ❑
No
Is the sample agitated after 45 minutes?
❑ Yes ❑
No
Are the following items documented:
Volume of sample analyzed? Note volume analyzed:
❑ Yes ❑ No
Date and time of sample analysis (settling start time)?
❑ Yes ❑ No
Time of agitation after 45 minutes of settling?
❑ Yes ❑ No
Sample analysis completion (settling end time)?
❑ Yes ❑ No
Are samples analyzed within 48 hours of collection?
❑ Yes ❑ No
Are results reported in ml/L?
❑ Yes
❑ No
IX Was -paper trail (oompanng contract ab and,an site data to DMR) a,
'
1�1
laroit20fi''
Y�s ,u❑:ale
performed�lf so, Irs'montts revewed =wY... µ;4 _ `
Xt ,ts oUow up bythe Laboratory C;ertificanon.prora rm regolmrnended?f ' .,4, ..t:0
Yes, ICI
XI. Additional comments:
The pH 7 buffer mV = -11.7 mVl
Please submit a copy of this completed form to the Laboratory Certification program at:
DWQ Lab Certification, Chemistry Lab, Courier # 52-01-01
Electronic copies may be emailed to linda.chavis(a�ncdenr.gov.
Revision 04/20/2012