NC0005762_Incident Report 200401059_20040517

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Incident Report
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Report Number: 200401059
Incident Type: Other
Incident Started: 05/17/04
County:
City:
Responsible Party:
First Name:
Middle Name:
Last Name:
Owner:
Address:
City/State/Zip:
Phone:
Permit
Material Category: Estimated Qty: UOM
Location of Incident:
Cause/Observation:
Stormwater outfall No. 3.
The main pump and lint filtration system failed the waste stream
backed up and partially filled the beck pit. The level rose to the point of
the exposed construction joint crack. This crack allowed process
wastewater from a carpet dye beck to seep into the stormwater tunnel.
The stormwater piping system belongs to Westpoint Stevens, the
leak occurred in a portion of the facility that is owned by Gulistan
Carpets. Westpoint provides wastewater treatment services for
Gullistan.
Action Taken:
The Gulistan plant stopped the beck dying process while repairs
were being made.
On -Site Contact:
First/Mid/Last Name:
Company Name:
Phone:
Pager/Mobile Phone:
Reported By:
First/Mid/Last Name:
Company Name:
Address:
City/State/Zip:
Phone:
Pager/Mobile Phone:
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Chemical Name Reportable Qty. lbs. Reportable Qty. kgs.
Directions:
The 003 outfall is located approximately 1100 feet due west of the southwest cor
Comments:
The repair of the leak should prevent future leaks at this location. The plant
Will continue to inspect all process wastewater flows in the vicinity of the
stormwater tunnel. The plant will continue to inspect the stormwater outfall
once a week.
Report Created 05/26/04 09:27. AM
Page 1

Incident Questions:
Did the Material reach the Surface Water? Unknown Surface Water Name?
Did the Spill result in a Fish Kill? No Estimated Number of fish?
If the Spill was from a storage tank indicate type.
(Above Ground or Under Ground)
Containment? Yes
Cleanup Complete? Yes
Standard Agencies Notified:
Agency Name Phone First Name M.I. Last Name Contact Date
Other Agencies Notified:
Agency Name Phone First Name M.I. Last Name Contact Date
DWQ Information:
Phone:
Date/Time:
Referred Via:
Report Taken By:
Did DWQ request an additional written report?
If yes, What additional information is needed?
Report Entered By: Regional Contact:
Report Created 05/26/04 09:27 AM Page 2

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WESTPOINT STEVENS
May 21, 2004
Mrs. Belinda Henson
North Carolina Department of Environment
And Natural Resources
Fayetteville Regional Office
225 Green Street - Suite 714
Fayetteville, NC 28301-5043
Re: Bypass Report
WestPoint Stevens Inc.
NPDES Permit No. NC0005762
Scotland County
Dear Mrs. Henson:
Co P•(- PA U L R AM-S
R_FR
mAy 2 2004
Please find enclosed the form entitled Sanitary Sewer, Pump Station and WWTP Spill
or Bypass Report Form. This report describes the bypass event reported to you on
Monday, May 17, 2004. Also enclosed is a pictorial account to supplement the report.
Please let me know if you have any questions or need additional information.
Copies:
Environmental
W. Adams
H. Benton
D. Daniel
P. Harris
POST OFFICE BOX 388, WAGRAM, NORTH CAROLINA 28396 • AREA 910 369-2231
3(j

Sanitary Sewer, Pump Station and WWTP Spill or Bypass Report Form
(Please Print or Type — Use Attachments if Needed)
Permittee: WestPoint Stevens — Wagram WWTP Permit Number: NC0005762 County:
Scotland
Incident Started: Date: 5/17/04 Time 10:50 a.m. (approximate)
Incident Ended: Date 5/17/04 Time 11:30 a.m.
Source of Spill / Bypass (Check One):
® Sanitary Sewer ❑ Pump Station ❑ Wastewater Treatment Plant
All of the water discharged was process wastewater. There was no sanitary waste
included.
Level of Treatment (Check One):
® None ❑ Primary Treatment ❑ Secondary Treatment ❑ Chlorination Only
Estimated Volume of Spill / Bypass: 600 gallons
A flow of 15 gallons per minute was observed. The pumping station was down for 40
minutes.
Did the Spill / Bypass reach the Surface Waters?
® Yes ❑ No
If yes, please list the following:
Volume Reaching Surface Waters: small portion of the 600 gallons Surface Water
Name: Swap area adjacent to stormwater outfall
Did the Spill / Bypass result in a Fish Kill?
❑Yes ®No
Location of the Spill / Bypass:
Storm Water Outfall No. 3 (SW3). This outfall is located approximately 1,100 feet due
west of the southwest corner of the main building in the Wagram Complex. SW3 is 1,200
feet due east of Shoe Heel Creek
Cause of the Spill / Bypass:
Inside the plant, there is a tunnel that collects stormwater from interior roof drains of
WestPoint Stevens' Warehouse No. 1 and Fabrication 1 plants and the Gulistan Carpet
operation. This tunnel crosses the parking lot (collecting stormwater from yard drains) and
discharges in a wooded area behind the facility. The tunnel runs east to west. Inside the
Gulistan plant a series of dye becks are installed to dye carpet. A large drainage pit
running north to south is installed under this series of dye becks. The drainage pit empties
at the south end of the pit and flows outside to a large open, in -ground tank adjacent to

the main pumping and lint filtration system. The flow is then pumped through the filter
and into the main waste stream to the waste treatment plant.
The north end of the beck pit (adjacent to the south side of the drainage tunnel) was
modified during the late 1990's with the removal of one of the becks. A crack in a
construction joint associated with this modification, near the top of the beck pit had been
exposed with a slight settling of the concrete.
When the main pumping and lint filtration system failed the waste stream backed up and
partially filled the beck pit. At the same time, with the becks emptying into the pit, the
level rose to the point of the exposed construction joint crack. This crack allowed process
wastewater from a carpet dye beck to seep into the stormwater tunnel. Although the
stormwater piping system belongs to WestPoint Stevens (WPS), the leak occurred in a
portion of the facility that is owned by Gulistan Carpets. WPS provides wastewater
treatment services for Gullistan.
Describe the Repairs Made: The color of the bypassed flow at the outfall made it easy to
locate the. source. A wooden form was constructed around the crack and filled with
grout. A manhole outside of the plant allowed verification that process water had stopped
entering the stormwater tunnel.
Action Taken to Contain Spill, Clean Up Waste and Remediate the Site: The Gulistan
Plant stopped their beck dying operation while repairs were being made to the pumping
station. This allowed the level in the pit to drop below the cracked construction joint and
prevented any further flow from entering the stormwater tunnel. The bypass was confined
to the main retention area at SW3 and pockets of retention in the immediate area. Brian's
Waste Recycling was immediately called and pumped the retention area to their truck.
Pumping continued until clear water was seen flowing back from the downstream
retention areas. The bypassed material was then pumped from the truck into the Gulistan
main pumping station pits, pumped and filtered to the waste treatment plant. A total of
11,000 gallons was removed from the area. The bypassed flow was sampled and tested at
two places for color and pH. The results for pH were 6.42 and 6.59; color was 814 and
872 ADMI units. Routine samples taken that morning tested a pH of 6.28, a temperature
of 26 C and a flow of 3.5 gallons per minute.
Action Taken or Proposed to be Taken to Prevent Future Spills at this Location:
The repair of the leak should prevent future leaks at this location. The plant will continue
to inspect all process wastewater flows in the vicinity of the stormwater tunnel. The plant
will continue to inspect the stormwater outfall once a week.

WestPoint Stevens
NPDES Permit No. NC0005762
Gulistan Bypass Event
May 17, 2004
Vird
Shoe Heel Creek
_
Storm Water Outfall No. 3 (SW'3) is located 1,100 due west
Of the SW corner of the Weslloint Stevens operation
And is 1,200 fee due east of Shoe Ileel Creek
Lumber River
1

A Tunnel inside Warehouse No. I, Fabrication No. 1 and the Gulistan Operation
Collects stormw'ater from the roof and drains to
Stormwater Outfall 3 (SW3)
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Gulistan Operation - Source of Bypass
The main pumping and lint filtration system failed causing
the waste stream to fill the pits.
2

Gulistan Operation - Source of Bypass
The failure caused the waste stream to back up into the plant
and fill the drainage pit under the dye becks
Gulistan Operation - Source of Bypass
The filled pit flowed over into a crack in a construction joint
adjacent to the storm drainage tunnel
3

Gulistan Operation - Source of Bypass
Once the pumps were started and the level lowered in the
outside pit, the leak inside was stopped
Gulistan Operation - Source of Bypass
A form was constructed at the crack and filled with a grout
Elevation view from within the pit
View from the top of the pit
4

The resulting bypass was noted immediately by personnel
working in the area minimizing the volume bypassed
Bypass Containment and Clean Up
Bypass was contained to the main retention area and pockets
of retention in the immediate area
5

Bypass Containment and Clean Up
Brian's Waste Recycling was called to clean up the site
Bypass Containment and Clean Up
Brian's Waste Recycling was called to clean up the site
6

Bypass Containment and Clean Up
Brian's Waste Recycling pumped the bypassed material from
the retention area into their truck
Bypass Containment and Clean Up
Brian's Waste Recycling pumped the bypassed material from
the retention area into their truck
7

Bypass Containment and Clean Up
The bypassed material was then deposited into the pits,
filtered and pumped to the waste treatment plant
Bypass Containment and Clean Up
The bypassed material was then deposited into the pits,
filtered and pumped to the waste treatment plant
8

Bypass Containment and Clean Up
Pumping continued until clear water was noted flowing from
the outfall
Bypass Containment and Clean Up
Pumping continued until clear water was noted flowing back
from downstream retention areas
9

Using robotic cameras the entire storm tunnel was inspected
SANITARY & STORM SEWER CLEANING
CCTV PIPE INSPECTION
10