NC0005762_Inspection_20020910

r
NCDENR
North Carolina Department of Environment and Natural Resources `l ! I JQ�
Michael F. Easley, Governor William G. Ross, Jr., Secretary -73,44
Alan Klimek, P.E., Director
September 10, 2002 Division of Water Quality
Mr. Yancy D. Helton, Division Director of Engineering
WestPoint Stevens, Inc.
PO Box 388
Wagram, NC 28396
SUBJECT: Compliance Evaluation Inspection
WestPoint Stevens, Inc.
Wastewater Treatment Plant
NPDES Permit No. NC0005762
Scotland County
Dear Mr. Helton:
Enclosed is a copy of the Compliance Evaluation Inspection conducted September 5, 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. Herman Benton, Grade IV ORC, Mr. George Brown, Grade IV Backup Operator
and Roy McGinn, Grade III Operator/Wastewater Chemist was appreciated. During the inspection
a copy of the NPDES Compliance Reminders were reviewed and left with Mr. Benton. 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. Herman Benton, ORC
Central Files
FRO Files
Fayetteville Regional Office
225 Green Street — Suite 714, Fayetteville, North Carolina 28301-5043
Phone: [phone]/FAX: [phone] Internet www.enr.state.nc.us/ENR
An Fn ial rinnnrti inity 1 Affim,ativa Artinn Fmnlnvar — .Fifl°,4, Ranvrlari 1 ink Pnst nnnnsi Imar Panar

NPDES COMPLIANCE INSPECTION REPORT
North Carolina Division of Water Quality
Fayetteville Regional Office
Section A. National Data System Coding
Transaction Code: N NPDES NO. NC0005762 Date: 020905 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:
West Point Stevens, Inc. WWTP
Entry Time/Date: 10:00am/020905 Permit Effective Date: 010101
Exit Time/Date: 1:30pm/020905 Permit Expiration Date: 040731
Name(s), Title(s) of On -Site Representative(s):
Herman Benton (Certified Grade IV) - "ORC"
George Brown (Certified Grade IV) - "Backup Operator"
Roy Guinn (Certified Grade III) - "Plant Chemist"
Phone Number(s): [phone]
Name, Title and Address of Responsible Official:
Mr. Yancy D. Helton, Division Director of Engineering
PO Box 388
Wagram, NC 28396
Contacted: no
Section C: Areas Evaluated During Inspection
(S = Satisfactory, M = Marginal, U = Unsatisfactory, N = Not Evaluated, N/A = Not Applicable)
Permit:
ecords[Reports'
;Facility Site Review:;'.
.aborafory
;P.retreatment
Self -Monitoring Program
ow;Measurement: : S:
-Effluent/Receivi ng _Waters::.
Compliance Schedule: NI
Operation &i`>Maintenance:
Sludge Disposal: S
.:,Other:

Mr. Yancy D. Helton
Page 3
September 10, 2002
Section D: Summary of Findings/Comments:
1. WestPoint Stevens manufactures approximately 1/4 of the home fashion towels in the United States.
2. The automatic bar screen was operational. The facility has purchased and installed a new steel
automatic bar screen since the last inspection. Screenings are dewatered and placed in a dumpster
where they are hauled to the county landfill when needed.
3. The two (2) influent screw pumps were operational. One (1) pump is used under ordinary flow
conditions. The influent pumps are alternated.
4. Flow is pumped from the "Headworks" to a 10 million gallon (MG) equalization (EQ) basin where
it is continuously mixed. It contains four (4) mixers. All mixers appeared to be operational. The EQ
basin assists with pH stabilization and color removal. Plans are to dredge the EQ basin in the near
future to assist with treating the wastewater.
5. The aeration basin appeared to be operating adequately with all aerators operating. The aeration
basin contains twelve (12) aerators and two (2) mixers. The facility has been replacing 60
Horsepower (HP) aerators with 75 Horsepower (HP) aerators to increase efficiency of treatment. The
facility has two (2) aerators left in their plan to replace. Some foam appeared on the surface of the
wastewater but not excessive. The most recent Mixed Liquor Suspended Solids (MLSS) result was
2098 mg/L.
6. Polymer is added in the flash mix area to the Mixed Liquor before it enters the clarifier to assist with
removing color and settleability when needed. At the time of the inspection polymer was not added.
The containment area around the 4500 gallon tank of poymer located beside the flash mix area
contained rainwater. A recommendation would be to pump this area out to assist with continuous
containment space for the polymer. The facility has been experiencing some filamentous growth
in its MLSS which has caused some settleability problems. The facility has been adding polymer to
assist with the settling problems.
7. The three (3) clarifiers appeared to be operational. The sludge depths were as follows:
Clarifier #1 - 4 '/2 feet with a tank depth of 12 feet
Clarifier #2 - 5 feet with a tank depth of 12 feet
Clarifier #3 - 3 '/2 feet with a tank depth of 12 feet.
The facility plans to either paint or replace the weirs of the clarifiers within this budget year as per
Mr. Benton. These areas in the clarifiers are in need of painting or replacing as part of maintaining
the wastewater facility.
8. The final aeration effluent tank where defoamer is added appeared to be operating adequately. The
aerator is 15 Horsepower (HP). The four (4) spouts which add defoamer to the effluent to reduce
foam were operational.
9. The effluent appeared to be free of visible solids.

Mr. Yancy D. Helton
Page 4
September 10, 2002
10. The composite effluent sample refrigerator temperature appeared to be 3.9 degrees Celsius. The
acceptable temperature range of samples during storage and for stored samples is 1.0 - 4.4 degrees
Celsius. The sample tubing appeared to be clean. At the end of the sample tubing located on the
strainer, there appeared to be some debris attached. A recommendation would be to remove the
debris as soon as possible to eliminate possible NPDES permit violations.
11. The effluent flow meter (Milltronics-Multi Ranger ) was calibrated June 12, 2002 by Nix, Purser and
Associates, Inc. It is advisable that the flow meter calibration document contain the % error before
and after calibration in the future by the technician. The flow chart ink supply had been replaced as
suggested in the last inspection report dated October 19, 2001.
12. The aerobic digester appeared to be operating adequately. The sludge is thickened in a filter belt
press from one (1) % to five (5)%. The filter belt press normally operates five (5) days per week.
The filtrate (water) from the sludge flows into the Headworks of the plant instead of directly to the
aeration basin which in the past was the flow pattern. This change was implemented recently to
assist with eliminating fecal coliform violations. Fecal coliform violations have not occurred since
this change was implemented. The sludge is land applied by "Synagro" (contract company) monthly
to permitted farm land under permit #WQ0002377.
13. Maintenance records are organized through Preventive Maintenance (P/M) work orders by facility
staff. Work orders are completed and documented by facility maintenance staff. All maintenance
records reviewed appeared to be adequate.
14. The laboratory on site is certified for eight (8) parameters. A field inspection check list for the field
parameters was completed during the records review and will be forwarded to our Laboratory
Certification Unit. All other NPDES permit required parameters are analyzed by "Microbac
Environmental Laboratory" (commercial laboratory) with the exception of the Toxicity which is
analyzed by "Similab".
15. Laboratory records were reviewed for November 2001, February and March 2002 and compared to
Discharge Monitoring Reports. Data appeared to be correctly reported.
16. The "Backup Operator" for this facility is George Brown -Grade IV certified operator.

Name and Signature of Inspector Agency/Office/Telephone Date
Belinda S. Henson f-'1`� -d 7won0 DENR/Fayetteville/[phone]
Name and Signature of Reviewer
Paul E. Rawls
Action Taken
Agency/Office/Telephone Date
DENR/Fayetteville/[phone]
Regulatory Office Use Only
Compliance Status
_Noncompliance
_Compliance
Date

Section D: Summary of Findings/Comments
Brief Facility Description:
A WWTP consisting of a mechanical bar screen, 10 MG equalization basin, 7 MG aeration basin.
clarifiers, aerobic digester, chemical feed system, gravity belt sludge thickener, sludge holding
tank. pot aeration. and effluent fow measurement.
FACILITY SITE REVIEW
Yeses No N/A 1. Treatment units properly operated and maintained.
Yes N9' N/A 2. Standby power or other equivalent provision provided.
Ts-5) No N/A 3. Adequate alarm system for power or equipment failure available.
4. Sludge disposal procedures appropriate:
No N/A a. Disposal of sludge according to regulations
Yes' No N/A b. State approval for sludge disposal received:
es No N/A 5. Sufficient sludge disposed of to maintain treatment process equilibrium.
Ire' 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.
No N/A 9. Plant is generally clean, free from open trash areas.
10. Screening:
Yes No N/ ' a. Manual
No N/A b. Mechanical
Yes N/A c. Buildup of debris
No N/A d. Screenings properly disposed of.
11. Grit Removal:;
Yes No W a. Excessive organic content in the grit chamber
Yes No N/A b. Excessive odors
Yes No N/A c. Grit properly disposed of.

Page 2
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
NO
No N/A
No N/A
No N/A
No N/A
No N/A
No N/A
No N/A
No N/A
No N/A.
12. Primary clarifier: '
a. Excessive gas bubbles
b. Black and odorous wastewater
c. Poor suspended solids removed
d. Excessive buildup of solids in center well of circular clarifier
e. Weirs level
f. Weir blockage •
g. Evidence of short circuiting
h. Lack of adequate scum removal
i. Excessive floating sludge
j. BrOken sludge scraper.
Yes No hly
Yes No NrA
Yes No N/A
Yes -No' N/A
• Yes No N/A
Yes No N/A
Yes No N/A
Yes No N/A
Yes CR :):) N/A
Yes 6,$) N/A
Yes 6 N/A
Yes N/A
Yes (NZ• N/A
Yes (g.•• N/,A
Yes • No /A
Yes No NA
Yes No N/A
Yes No N/A
Yes No N/A
13. Triclding Filter:,
• a. Trickling ponding(indicating clogged, media)
b. Leak at' Center column of trickling filter's distribution arms
c. Uneven distribution offlow on trickling filter surface
d.-- Uneven or discolored growth =-.- •i
e. Excessive sloughing, of growth
f .Odor
g. Clogging of trickling filter'ssdistribution arm orifices
h. Filter flies; worms, or snails.
14. • Activated Sludge Basins/Oxidation Ditches:
a. Dead. spots
b. Failure of surface aerators
c. Air rising in clumps
d. Dark foam or bad color:
e. Thick billows of white, sudsy foam
f. Air rising unevenly
g. Excessive air leaks in compressed air piping.
(
15. Stabilization Ponds/Lagoons:
a. Excessive weeds including duckweed in stabilization ponds
b. Dead fish or aquatic organisms
c. Buildup of solids around influent pipe
d. Excessive scum on surface. • -

•Page 3
16. Secondary Clarifier: ,
Yes CIR8 N/A a, Excessive gas bubbles on surface
- - Yes 'Si' N/A b. Level overflow weirs ' .
Yes (ISIP N/A c. Weir blockage
Yes (1 N/A d. Evidence of short circuiting
Yes qiii) N/A e. Excessive buildup of solids in center well of circular clarifier
Yes (5) N/A I Pin floc in overflow - -
CliTs) No N/A g. Effective scum rake '
Yes N' N/A h. Floating sludge on surface
Yes N3 N/A• i. Excessive high sludge blanket
Yes (ga N/A j. Clogged sludge withdrawal ports on secondary clarifier.
Yes No agiv
• Yes No N/A
YesNo N/A
Yes No N/A
Yes No N/A
Yes No N/A
Yes Nci
Yes No
Yes No
Yes No
Yes No
Yes No
Yes NO
Yes No
N/A
N/A
N/A
N/A
N/A
N/A
N/A
Filtration:
a. Filter surface clogging
b. Short filter run • •
c. Gravel displacement of filter media
d. Loss of filter Media during backwashing
- e. •Recycled filter backwash water hi excess. of 5 percent
f. Formation of mudballs in filter media.
18. Chlorination Unit:
a. Sludge buildup in contact chamber
b. Gas bubbles -
c. Floating scum and/or solids
d. Adequate ventilation of chlorine feeding room and storage area
e. NIOSH-approved 30 minute air pack
•f All standing chlorine cylinders chained in place
g. All personnel trained in the use of chlorine
h: Proper chlorine feed, storage, and reserve supply.
Yes No NIA) 19 Ultraviolet radiatiOn disinfection present and in use.
20. Dechlorination: •
Yes No Njk 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.
21. Aerobic Digester: •
Yes .(10 N/A •a. Excessive foaming in tank
Yes CEI5) N/A b. Noxious odor
Yes egsQ N/A c. Mechanical aeration failure
Yes 'So) N/A d. Clogging of diffusers.

Page 4
22. Anaerobic Digester:
Yes No a. Floating cover tilting
Yes No N/A b. Gas burner operative
CO
• Yes No M
Yes No ak
• Yes No (ffiiT)
Yes No
Yes No
Yes _ti) N/A.
No N/A
Yes N/A
Yes '133 N/A
Yes 159 N/A
Yes (gs: N/A.
Yes No RI
•Yes No N/A
Yes No N/A
Yes (KO) N/A
Yes (i43 N/A
Yes• No N/A
•Cre7) isio N/A
(rs:i No N/A
Yes cp N/A
Yes &ii) N/A
Yes No
Yes CID N/A
Yes No N/A
23.. Sludge Drying and/or disposal:
a. Poor sludge distribution on drying beds
b: Vegetation in drying beds
c. Dry sludge remaining in drying beds
d. Dry sludge stored on site
e. Filtrate from sludge drying beds returned to front of plant
f Sludge disposal through county landfill.
g. Sludge land applied.
24. Filter Press:
a. High level of solids in filtrate from filter presses or vacuum filters
b. Thin filter cake caused by poor dewatering
c. Sludge buildup on belts and/or rollers of filter press
d. Excessive moisture in belt filter press sludge cake.
25. Polishing Ponds or Tanks:
a. Objectionable odor, excessive foam, floating solids, or oil sheens on
water surface
b. Solids or scum accumulations in tank or at side of pond
c. Evidence of bypassed polishing ponds or tanks because of low
capacity.
26. Plant Effluent:
a. Excessive suspended solids, turbidity, foam, grease, scum; color, and
other macroscopic Particulate matter present
b. Potential toxicity (dead fish, dead plant at discharge)
c. Outfall discharge line easily accessible.
27. Flow Measurement: •
• a. Proper placement of flow measurement device
• 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%1.

Page 5
es�No. N/A.
(Y3 No N/A
No N/A
LY'a 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.
N/A
No N/A
es . No N/A
No
& No
No
No
Yet No
N/A
N/A
N/A
N/A
N/A
No N/A
No N/A
$e7 No N/A
es, No N/A
Yes No N/A
Yes No N/A
RECORDKEEPING AND REPORTING
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.
4. Analytical results consistent with data reported on DMRs.
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.
8 Expiration dates of pH buffers adequate.
9 All thermometers used in NPDES permit reporting is calibrated
annually with an NIST 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.

Yes No N/A 11. The NPDES. permit required. parameter Total Chlorine Residual is
analyzed by approved method.
Yes 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 N/A 13. Fecal coliform incubator maintained at.44.5 +/- 0.2 Degree Celsius and
the temperature maintained in a log for every day of operation.
Yes No . N/A
Yes No . N/A
Yes No N/A
Yes . No N/A
14. Plant records adequate and include:
a. O. & .M Manual
b. "As -built" engineering drawings
c. Schedules and dates of equipment maintenance repairs
d.. Equipment data cards.
Yes No N/A 15.. Permittee is meeting, compliance schedule.
Yes No N/A 16. DMRs complete and include all NPDES permit required parameters.
Yes No N/A 17. The facility has a permitted flow greater than 5 MGD and is required
to operate seven days per week 24 hours a day.
Yes No N/A 18. ORC visitation logs available and current.
Yes No N/A 19. ORC certified at a level equal to orgreater than the classification of
the wastewater facility.
Yes No N/A 20. Backup Operator certified at one level less than the classification of
the wastewater facility or greater.
Yes No N/A 21. Current copy of the complete NPDES permit on site.
Yes No N/A. 22. Facility description verified as contained in NPDES permit.
Yes No N/A 23. Facility analyzes process control parameters for example: MLSS,
MCRT, Settleable Solids and others that. are applicable.
Yes No N/A 24. • Industrial Waste Surveys (IWS) sent to all possible Significant
Industrial Users (SIUs) within the last five years (especially new
industries).
Revised 7/16/01
by Belinda Henson

Regional Field Inspectors Check List for t•teia earamezers
Name of site to be Inspected: la\asi- Pr: evco s :.. Dater. : - 5 -�`
Field certification # (if applicable): \ Inspector: Re;i; nr/n.: S. Heviso:2-u
NPDES #: IVC..-00 ? 53 1 Region: Fct et
I. Circle the parameter or parameters performed at this site..
Residual Chlonrseep Settleable Solids, Conductivity empera ur
II. Instrumentation:
A. Does thefacility have the equipment necessary to analyze field parameters as circled above?
1. A pH meter 6a)
2. A Residual Chlorine meter (Ye7
3. - DO meter
4. A Cone for settleable solids
5. A thermometer or meter that measures temperature.
6. Conductivity'meter
III. CalibrationlAnalysis:.
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 Yes?
analyzed each day of use?
3. Is the air calibration of the DO meter performed
each day of use?
4. For Settleable- SoiidS, is 1 liter of sample Yes
settled for 1 hour?
5. Is the temperature measuring device calibrated
annually against a certified thermometer?'
6. For Conductivity, is a calibration standard Yes
analyzed each day of use?
es�
Yes
Yes
es
No
No
No
No
No
No

IV. Documentation:
1. Is the date and time that the sample was collected documented? rye
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 sai ple,:volurne° and_;
1 hourr time settling time documented? -
8. For Temperature, is the annual calibration of
the measuring device documented?
Comments:
(es)
No
No
0
No
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. 04/23/2002