NC0005762_Inspection_20070521

Michael F. Easley, Governor
William G. Ross Jr., Secretary
North Carolina Department of Environment and Natural Resources
Alan W. Klimek, P.E. Director
Division of Water Quality
May 21, 2007
Mr. Yancy Helton
WestPoint Stevens
P. O. Box 388
Wagram, North Carolina 28396
SUBJECT: May 17, 2007 Compliance Evaluation Inspection
WestPoint Stevens, Wagram Plant
WestPoint Stevens WWTP
NPDES Permit NC0005762
Scotland County
Dear Mr. Helton:
Enclosed please find a copy of the Compliance Evaluation Inspection form from the inspection conducted on
May 17, 2007. The cooperation of Anthony Chavis, Grade IV ORC, Ronald Locklear, Temporary Grade III
Back-up operator, and Fred Lowry was greatly appreciated. The Compliance Evaluation Inspection was
conducted by Mark Brantley, Environmental Chemist, of the Fayetteville Regional Office. The facility was found
to be in Compliance with permit NC0005762. As a reminder, preservation of the Waters of the State can only be
achieved through consistent NPDES Permit compliance.
COMMENTS
• The wastewater plant was clean and neat at the time of the inspection.
• The DMR's for the months of October 2006, December 2006, and February 2007 were compared to the
laboratory bench sheets and appeared to be in order at the time of the inspection.
• The bar screen is running constantly which is allowing unnecessary wear and tear on the unit. This may
cause the bar screen's life expectancy to be, reduced greatly. The facility may consider installing a float.
switch with a high level alarm to reduce the wear and tear on the bar screen.
• It was noted during the inspection that a white fluffy foam completely covered the aeration basin and the
aerated lagoon. It appears that this may caused by over aeration since all of the aerators were in
operation and the dissolved oxygen levels in the effluent were between 11-14 mg/1 oxygen.
• The Fayetteville Regional Office has on staff a Wastewater Treatment Consultant, Mr. Don Register, that
is available to provide technical assistance. It is strongly encouraged that you contact Mr. Register to
make a technical assistance visit in order to help the wastewater treatment plant operate moreefficiently
since the flow is at a fraction of what it used to be before the manufacturing process closed. (That is
reducing the amount of foam present and finding ways to reduce wear and tear on mechanical treatment
units.) Mr. Register can be reached at [phone].
NO_ 7thCarolina
aturalty
North Carolina Division of Water Quality 225 Green Street -Suite 714 Fayetteville, NC 28301 Phone [phone] Customer Service
Internet: www.ncwaterquality.org
Fax [phone]
An Equal Opportunity/Affirmative Action Employer — 50% Recycled/10% Post Consumer Paper

• Comments concerning clarifiers:
Clarifier number 1- The weir plate and baffles were wearing and rusting very thin. Please
either paint these items or consider replacing with fiberglass parts to ensure proper operation.
Clarifier number 2- This clarifier was in operation at the time of the inspection. When this
clarifier is taken down for maintenance please inspect and determine if it needs painting to protect
it from rusting.
Clarifier number 3- The weir plate, baffle, and center well of this clarifier needs painting to
protect metal from rusting. Painting now may help avoid costly repairs in the future.
• A violation report covering the months of July 2006 through April 2007 revealed 5 Daily Maximum Fecal
Violations.
Please refer to the enclosed inspection report for additional observations and comments. If you or your staff have
any questions, please call me at 910-433-3300.
Sincerely,
)44
Mark Brantley
Environmental Chemist
Surface Water Protection Section
Fayetteville Regional Office
Cc: Anthony Chavis, ORC
Central Files
Fayetteville Files

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 I NI 2 I sl. 3I NC0005762 1 11' 121 07/05/17 1 17
Type Inspector Fac Type
181 cl 191 sl 20I II
Li
Remarks
211111111111111.1111111111111111111111.11111111111166
Inspection Work Days Facility Self -Monitoring Evaluation Rating B1 QA Reserved------- ---------- =--
67 I 169 701 31 7,11 NI 721 NI "I 174 751 l l l l l l l 80
• Section B: Facility Data
Name and Location of Facility Inspected (For Industrial Users discharging to POTW, also include
POTW name and NPDES permit Number)
Wagram plant
NCSR 1407 -
Wagram NC 28396
Entry Time/Date
08-:30 AM 07/05/17
Permit Effective Date
05/08/01
Exit Time/Date
12:00 PM 07/05/17
Permit Expiration Date
09/07/31'
Name(s) of Onsite Representative(s)/Titles(s)/Phone and Fax Number(s)'
///
Anthony Lynn Chavis/ORC/910-369-4244/
Other Facility Data
Name, Address of Responsible Official/Title/Phone and Fax Number
Contacted
Yancy D Helton,PO Box 338 Wagram NC 28396//910-369-4111/9103694380
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 Compliance Schedules
Effluent/Receiving Waters Laboratory
Section D: Summary 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//910-433-3300 Ext.727/
Signature of Management Q A Reviewer Agency/Office/Phone and Fax Numbers Date
Belinda S Henson FRO WQ//910-433-3300 Ext.726/
EPA Form 3560-3 (Rev 9-94) Previous editions are obsolete.
Page # 1

31
NPDES yr/mo/day Inspection Type
NC0005762
111 121 07/05/17 1
17 181
C1
(cont.) 1
Section D: Summary of Finding/Comments (Attach additional sheets of narrative and checklists as necessary)
COMMENTS
The wastewater plant was clean and neat at the time of the inspection.
The DMR's for the months of October 2006, Decem ber 2006, and February 2007 were compared to the
laboratory bench sheets and appear ed to be in order at the time of the inspection.
The bar screen is running constantly which is all owing unnecessary wear and tear on the unit. This may
cause the bar screen's life expectancy to be reduced greatly. The facility may consider installing a float
switch with a high level alarm to reduce the wear and tear on the bar screen.
It was noted during the inspection that a white fluffy foam c ompletely covered the aeration basin and the
aerated lagoon. It appears that this m ay be caused by over aeration since all of the aerators were in
operation and the dissolved oxygen levels in the effluent were between 11-14 mg/I oxygen.
The Fayetteville Regional Office has on staff a Wastewater Treatment Consultant, M r. Don Register, that is
available to provide technical assistance. It is strongly encouraged that you contact M r. Register to make a
technical assistance visit in order to help the wastewater treatment plant operate more efficiently since the
flow is at a fraction of what it used to be before the manufacturing process closed. (That is reducing the
amount of foam present and finding ways to reduce wear and tear on mechanical treatment units.) Mr.
Register can be reached at [phone].
Comments concerning clarifiers:
Clarifier number 1- The weir plate and baffles were wearing and rusting very thin. Please
either paint these items or consider replacing with fiberglass parts to ensure proper operation:
Clarifier number 2- This clarifier was in operation at the tim e of the inspection. When this clar ifier is taken
down for maintenance please inspect and determine if it needs painting to protect it from rusting.
Clarifier number 3- The weir plate, baffle, and center well of this clarifier needs painting to protect m etal
from rusting. Painting now may help avoid costly repairs in the future.
A violation report covering the months of July 2006 through April 2007 revealed 5 Daily Maximum Fecal
Violations.
Page # 2

Permit: NC0005762 Owner - Facility: • Wagram plant
Inspection Date: 05/17/2007 Inspection Type: Compliance Evaluation
Compliance Schedules Yes No NA NE
Is there a compliance schedule for this facility? ■ ❑- ❑ ❑
Is the facility compliant with the permit and conditions for the review period? n ■ n n
Comment: Facility had several daily maximium fecal violations in the months of
January and February 2007.
Operations & Maintenance Yes No NA NE
Is the plant generally clean with acceptable housekeeping? ■ Finn
Does the facility analyze process control parameters, for ex: MLSS, MCRT, Settleable Solids, pH, DO, Sludge ■ n n n
Judge, and other that are applicable?
Comment: Facility uses MLSS, settleable solids, pH, dissolved oxygen levels and
sludge blankets as process controls.
Permit Yes No NA NE
(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? • n ❑ ❑
# Are there any special conditions for the permit? ❑ n ■
Is access to the plant site restricted to the general public? • ❑ ❑ n
Is the inspector granted access to all areas for inspection? • ❑ El 11
Comment:
Record Keeping Yes No NA NE
Are records kept and maintained as required by the permit? ■ n n ❑
Is all required information readily available, complete and current? • ❑ ❑ n
Are all records maintained for 3 years (lab. reg.'required 5 years)? ■ n ❑ ❑
Are analytical results consistent with data reported on DMRs? ■ ❑ n n
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 1
Name of person performing analyses ■ .
Transported COCs ■
Are DMRs complete: do they include all permit parameters? • ElEl
El
Has the facility submitted its annual compliance report to users and DWQ? n ❑ ■
Page # 3

Permit: NC0005762 Owner - Facility: Wagram plant
Inspection Date: 05/17/2007 Inspection Type: Compliance Evaluation
Record Keeping
(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?
Facility has copy of previous year's Annual Report on file for review?
Comment:
Effluent 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:
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: The meter was last calibrated in November 2006 by Carolina Technical Inc.
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: The meter was last calibrated in November 2006 by Carolina Technical Inc.
Yes No NA NE
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Yes No NA NE
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Aerobic Digester Yes No NA NE
Is the capacity adequate? ■ ❑ ❑ n
Is the mixing adequate? ■ ❑ ❑ ❑
Is the site free of excessive foaming in the tank? • n ❑ El
Page # 4

to 1
Permit: NC0005762
Inspection Date: 05/17/2007
Owner - Facility: Wagram plant
Inspection Type: Compliance Evaluation
Aerobic Digester Yes No NA NE
# Is the odor acceptable? E ❑ n n
# Is tankage available for properly waste,sludge? ■ n n n
Comment: The WWTP has not had to waste sludge since the m ain manufacturing site
has shut down.
Solids Handling Equipment Yes No NA NE
Is the equipment,operational? n ❑ ■ n
Is the chemical feed equipment operational? n n ■ n
Is storage adequate? n ❑ ■ ❑
Is the site free of high level of solids in filtrate from filter presses or vacuum filters? n n ■ n
Is the site free of sludge buildup on belts and/or rollers of filter press? ❑ n ■ n
Is the site free of excessive moisture in belt filter press sludge cake? n ❑ ■ n
The facility has an approved sludge management plan? ■ n n . n
Comment: The facility has not operated the filter press in the past 4 months.
Chemical Feed Yes No NA NE
Is containment adequate? ■ n n ❑
Is storage adequate? • n n n
Are backup pumps available? ■ n n n
Is the site free of excessive leaking? ' • n n n
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
Are all pumps operable? ■ n n n
Are float controls operable? - ❑ ❑ • n
Is SCADA telemetry available and operational? - n n ■ n
Is audible and visual alarm available and operational? n n ■ n
Comment:
Bar Screens Yes No NA NE
Type of bar screen
Page # 5

Permit: NC0005762 Owner - Facility: Wagram plant
Inspection Date: 05/17/2007 Inspection Type: Compliance Evaluation
Bar Screens
a.Manual
b.Mechanical
Are the bars adequately screening debris?
Is the screen free of excessive debris?
Is disposal of screening in compliance?
Is the unit in good condition?
Comment:
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: Pumps are variable speed and are adjusted manually.
Secondary Clarifier
Is the clarifier free of black and odorous wastewater?
Is the site free of excessive buildup of solids in center well of circular clarifier?
Are weirs level?
Is the site free of weir blockage?
Is the site free of evidence of short-circuiting?
Is scum removal adequate?
Is the site free of excessive floating sludge?
Is the drive unit operational?
Is the return rate acceptable (low turbulence)?
Is the overflow clear of excessive solids/pin floc?
Is the sludge blanket level acceptable? (Approximately'/< of the sidewall depth)
Yes No NA NE
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Yes No NA NE
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Yes No NA NE
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sin El
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Page # 6

Permit: NC0005762 Owner - Facility: Wagram plant
Inspection Date: 05/17/2007 Inspection Type: Compliance Evaluation
Secondary Clarifier Yes No NA NE
Comment:
Aeration Basins Yes No NA . NE
Mode of operation Ext. Air
Type of aeration system Fixed
Is the basin free of dead spots? ■ n n n
Are surface aerators and mixers operational? - ■ ❑ n ❑
• Are the diffusers operational? ❑ 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 ❑ ❑
Is the DO level acceptable?(1.0 to 3.0 mg/I) ■ ❑ ❑ ❑
Comment: Foam covers 100% of basins, please talk with consultant about cutting
back on the number of aerators in service at one time
Standby Power Yes No NA NE
Is'automatically activated staridby•power available? ❑ .n ■ n
Is the generator tested by interrupting primary power source? ❑ ❑ ■
Is the generator tested under load.? - n ❑ ■
Was generator tested & operational during the inspection? ❑ ❑ •
1-1
Do the generator(s) have adequate capacity to operate the entire wastewater site?. noun
Is there an emergency agreement with a fuel vendor for extended run on back-up power? n ❑ • n
Is the generator fuel level monitored? ❑ ❑ • ❑
Comment: The EQ Basin can hold overflow until power is restored. If power fails then
the production stops.
Pumps-RAS-WAS . Yes No NA NE
Are pumps in place? • ❑ n ❑
Are pumps operational? ■ n ❑ ❑
Are there adequate spare parts and supplies on site? • El
Comment: ,
Laboratory Yes No NA NE
Are field parameters performed by certified personnel or laboratory? • ❑
Are all other parameters(excluding field parameters) performed by a certified lab? ■ , ❑ ❑ ❑
Page # 7

A
Permit: NC0005762 Owner - Facility: Wagram plant
Inspection Date: 05/17/2007 Inspection Type: Compliance Evaluation
Laboratory Yes No NA NE
# Is the facility using a contract lab? ■ n n n
Is proper temperature set for sample storage (kept at 1.0 to 4.4 degrees Celsius)? 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: Facility uses MicroBac labs (for TRC, Fecal, Phenol, and Tox) and TBL
labs (for BOD, COD, and TSS).
Influent Sampling Yes No NA NE
# Is composite sampling flow proportional? • n ❑ • ❑
Is sample collected above side streams? ■ n ❑ n
Is proper volume collected? ■ ❑ n ❑
Is the tubing clean? ■ n n n
Is proper temperature set for sample storage (kept at 1.0 to 4.4 degrees Celsius)? • n ❑ n
Is sampling performed according to the permit? ■ n n n
Comment: The sampler temperature was at 4 degrees celsius.
Effluent Sampling Yes No NA NE
Is composite sampling flow proportional? ❑ ❑ 1 ❑
Is sample collected below all treatment units? • n n n
Is proper volume collected? .. • ❑ ❑ n
Is the tubing clean? • n n n
Is proper temperature set for sample storage (kept at 1.0 to 4.4 degrees Celsius)? • n ❑ n
Is the facility sampling performed as required by the permit (frequency, sampling type representative)? ■ n n n
Comment: The sampler temperature was at 2 degrees Celsius.
Upstream / Downstream Sampling Yes No NA NE
Is the facility sampling performed as required by the permit (frequency, sampling type, and sampling location)? ■ n n n
Comment:
Page # 8

Regional Field Inspectors Check List for Field Parameters
Name of site to be Inspected: YP sj�c„.rns Date: (S/T p 7
Field Certification # (if applicable): / ,S6c Inspector: "4.4.,,' Q
NPDES #: ,YCoop .SS76.2 Region: F/ 0
I. Circle the parameter or parameters performed at this site.
Residual Chlorine, Settleable Solids,, DO, Conductivity, Temperature
II. Instrumentation:
A. Does the facility have the equipment necessary to analyze field parameters as circled above:
1. A pH meter O/2m, mock/ 1/42 o 4-
2. A Residual Chlorine meter uses
3. DO meter
4. A Cone for settleable solids
H., model
No
Yes No
No
Yes
5. A thermometer or meter that measures temperature es
6. Conductivity meter O,? o N rt adc
III. Calibration/Analysis:
1. Is the pH meter calibrated with a 2 buffers and checked
with a third buffer each day of use?
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? Yes
4. For Settleable Solids, is 1 liter of sample settled for 1 hour? Yes
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
No.
No
No pit "% -i1� -uy
/,,fr•<v
No
No

IV. Documentation:
1. Is the date and time that the sample was collected documented
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?
No
No
No
No
No
No
8. For Temperature, is the annual calibration of the measuring
device documented Yes No
Comments:
r yc�1'i. i`s C �..117 CC*4'4 /. �:. /�1-0 Q oH `/ 1 c€KI /c e41,
-W+�' LL `d, ''e, . Crali,�rsa r wi r9 u 7 / /U dI. J
tti- rg 4 �.
vi-r / Vaase u► tt i-A/47 rAe„m.o-..,,c.
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. 02/14/2007