NC0005762_Inspection_20011019

ATA
NCDENR
North Carolina Department of Environment and Natural Resources
Michael F. Easley, Governor
October 19, 2001
Mr. Yancy D. Helton, Division Director of Engineering
WestPoint Stevens, Inc.
POBox388
Wagram, NC 28396
SUBJECT: Compliance Evaluation Inspection
WestPoint Stevens, Inc.
Wastewater Treatment Plant
NPDES Permit No. NC0005762
Scotland County.
Dear Mr. Helton:
ID/aato13414
William G. Ross Jr., Secretary
Gregory J. Thorpe, Ph.D.
Acting Director
Division of Water Quality
Enclosed is a copy of the Compliance Evaluation Inspection conducted October 9, 2001.
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. George Brown, Grade IV Backup Operator and Roy McGinn, Grade III
Operator/Wastewater Chemist. 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
Qvy1,(3 ,x2. 9 t�YLc2,0-ry
Belinda S. Henson
Environmental Chemist
/bsh
Enclosures
cc: Mr. Herman Benton, ORC
Central FilesR
_FROFiles`'--' _- Fayetteville Regional Office
225 Green Street- Suite 714, Fayetteville, North Carolina 28301-5043
Phone: [phone] FAX: [phone] Internet: www. enr. state.nc.usfENR
An Equal Opportunity 1 Affirmative Action Employer - 50% Recycled 110% Post Consumer Paper

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: 011009 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: 10:00am Permit Effective Date: 010101
Exit Time/Date: 1:30pm/011009 Permit Expiration Date: 010731
Name(s), Title(s) of On -Site Representative(s):
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: yes
Section C: Areas Evaluated During Inspection
(S = Satisfactory, M = Marginal, U = Unsatisfactory, N = Not Evaluated, N/A = Not Applicable)
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Mr. Yancy D. Helton
Page3
October 19, 2001
Section D: Summary of Findings/Comments:
1. Tlie automatic bar screen was operational. There appeared to be numerous teeth missing in the racks
of the bar screen. As a reminder the missing teeth were noted in the previous report dated
February 10, 2000. Please respond to this item in writing to our office by November 30, 2001.
All screenings are disposed of by ARS.
2. The two (2) influent screw pumps were operational. One (1) pump is used under ordinary flow
conditions. The influent pumps are alternated.
3. Flow is pumped from the "Headworks" to a 10 million gallon (MG) equalization basin where it is
continuously mixed. It contains four (4) mixers. All mixers appeared to be operational.
4. The aeration basin appeared to be operating adequately. The aeration basin contains ten (10) aerators
with two (2) under repair at the time of the inspection. Some foam appeared on the surface of the
wastewater but not excessive. The most recent Mixed Liquor Suspended Solids (MLSS) result was 1900
mg/L with settleability around 900 ml/L.
5. Polymer was added in the chemical feed contact area to the Mixed Liquor before it enters the clarifier
to assist with removing color and settleability.
6. The three (3) clarifiers were operational. The sludge depths were less than (<) eight (8) feet with a tank
depth of twelve (12) feet.
7. The final aeration effluent tank where defoamer is added appeared to be operating adequately. The four
(4) spouts which add defoamer to the effluent to reduce foam were operational.
8. The effluent appeared to be free of visible solids.
9. The composite effluent sample refrigerator temperature appeared to be three (3) 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.
10. The effluent flow meter was calibrated June 25, 2001 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 was empty so therefor the flow chart could not
document the flow. Please replace the ink immediately to document the flow.
11. The sludge is thickened in a filter belt press from less than (<) one (1) % to five (5)%. The filter belt
press normally operates five (5) days per week. The sludge is land applied by "Synagro" (contract
company) to permitted farm land under permit#WQ0002377.

Mr. Yancy Helton
Page 4
October 19, 2001
12. Maintenance records are organized through Preventive Maintenance (P/M) work orders by facility staff.
13. The laboratory on site is certified for eight (8) parameters. 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".
14. Laboratory records were reviewed for January and February 2001 and compared to Discharge
Monitoring Reports. Data appeared to be correctly reported.
15. A compliance evaluation report for the period September 2000 through August 2001 did not reveal any
monthly violations. Notice of Violations were submitted to the facility for January and March 2001 for
weekly Fecal Coliform violations.
Name and Signature of Inspector
Belinda S.
�H��enson j)
Name and Signature of Reviewer
Paul E. Rawls
Action Taken
Agency/Office/Telephone Date
DENR/Fayetteville/(910)48 6-1541
Agency/Office/Telephone Date
DENR/Fayetteville/[phone]
Regulatory Office Use Only
Compliance Status
_Noncompliance
_Compliance
Date
1

Section D: Summary of Findings/Comments
Brief Facility Description:
WestPoint Stevens Incorporated WWTP consisting of a mechanical bar screen, 10 MG
equalization basin, 7 MG aeration basin, three (3) clarifiers, aerobic digester, chemical feed
system, gravity belt sludge thickener, sludge holding tank, post aeration, effluent flow
measurement.
FACILITY SITE REVIEW
Yes No N/A 1 Treatment units properly operated and maintained.
Yes (�T_9? N/A 2. Standby power or other equivalent provision provided.
Yes N/A 3. Adequate alarm system for power or equipment failure available.
n No N/A
No N/A
4. Sludge disposal procedures appropriate:
a. Disposal of sludge according to regulations
b. State approval for sludge disposal received.
No N/A 5. Sufficient sludge disposed of to maintain treatment process equilibrium.
Yes No N/A 6. The ORC and Backup Operator are officially designated •with
NCDENR/DWQ Training and Certification Unit.
Yes No N/A 7. Adequate spare parts and supplies inventory maintained.
__es') No N/A 8. Plant has general safety structures such as rails around or covers over
tanks, pits, or wells.
1. No N/A 9. Plant is generally clean, free from open trash areas.
10.
Yes No
No N/A
Yes N/A
No N/A
11.
Yes No
Yes No N/A
Yes No N/A
Screening:
a. Manual
b. Mechanical
c. Buildup of debris
d. Screenings properly disposed of.
Grit Removal:
a. Excessive organic content in the grit chamber
b. Excessive odors
c. Grit properly disposed of.

Page 2
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
No
No
No
No
No
No
No
No
No
No
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
No \
No N/A
No N/A
No N/A
No N/A
No N/A
No N/A
No N/A
Yes N/A
Yes No N/A
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
'No) N/A
a' N/A
gO) N/A
No&lAA
No IA
No 1/
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.
13. Trickling Filter:
Trickling filter ponding(indicating clogged media)
Leak at center column of trickling filter's distribution
Uneven distribution of flow on trickling filter. surface
Uneven or discolored growth
Excessive sloughing of growth
Odor
Clogging of trickling filter's distribution arm orifices
Filterflies, worms, or snails.
a.
b.
c.
d.
e.
f.
g.
h.
1.4. 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.
arms
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 a N/A a. Excessive gas bubbles on surface
Yes N N/A b. Level overflow weirs
Yes & N/A c. Weir blockage
Yes "' N/A d. Evidence of short circuiting
Yes U1 N/A e. Excessive buildup of solids in center well of circular clarifier
Yes No N/A f. Pin floc in overflow some, f r1 N- tb e 0 o f ex e eSs = ue
No N/A g. Effective scum rake
Yes CV9 N/A h. Floating sludge on surface
Yes ab NIA i. Excessive high sludge blanket
Yes J&j N/A j. Clogged sludge withdrawal ports on secondary clarifier.
Yes No Q(�'
Yes No N/A
Yes No N/A
Yes No N/A
Yes No N/A
Yes No N/A
17. Filtration:
a. Filter surface clogging
b. Short filter nun
c. Gravel displacement of filter media
d. Loss of filter media during backwashing
e. Recycled filter backwash water in excess of 5 percent
f Formation of mudballs in filter media.
18. Chlorination Unit:
Yes No / a. Sludge buildup in contact chamber
Yes No N/A b. Gas bubbles
Yes No N/A c. .Floating scum and/or solids
Yes No N/A d. Adequate ventilation of chlorine feeding room and storage area
Yes No . N/A e. NIOSH-approved 30 minute air pack
Yes No N/A f All standing chlorine cylinders chained in place
Yes No N/A g. All personnel trained in the use of chlorine
Yes No N/A • h. Proper chlorine feed, storage, and reserve supply.
Yes No N% 19. Ultraviolet radiation disinfection present and in use.
20.
Yes No I►s
Yes No N/A
Yes No N/A
21.
Yes caiD N/A
Yes ) N/A
Yes No • N/A
Yes No N/A
Dechlorination:
a. Proper storage of sulfur dioxide cylinders
b. Adequate ventilation of sulfur dioxide feeding room
c. Automatic sulfur dioxide feed or feedback control operating
properly.
Aerobic Digester:
a. Excessive foaming in tank
b. Noxious odor
c. Mechanical aeration failure
d. Clogging of diffusers.

(fie` J No N/A
Yes; No N/A
Yes N/A
Yes (go N/A
Yes N/A
Yes N/A
Yes No N/A
Page 4
22. Anaerobic Digester:
Yes No VIP a. Floating cover tilting
Yes No N/A b. Gas burner operative
23. Sludge Drying and/or disposal:
Yes No a. Poor sludge distribution on drying beds
Yes No /� b. Vegetation in drying beds
Yes No G c. Dry sludge remaining in drying beds
Yes No ak d. Dry sludge stored on site
Yes No 1V1— e. Filtrate from sludge drying beds returned to front of plant
Yes No f Sludge disposal through county landfill.
Yet No N/A g. Sludge land applied.
Yes 60 N/A.
Yes N/A
Yes &i) N/A
Yes N/A
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:
Yes No ga a. Objectionable odor, excessive foam, floating solids, or oil sheens on
water surface
Yes No N/A b. Solids or scum accumulations in tank or at side of pond
Yes No N/A c. Evidence of bypassed polishing ponds or tanks because of low
capacity.
26. Plant Effluent:
Yes G.o) N/A a. Excessive suspended solids, turbidity, foam, grease, scum, color, and
other macroscopic particulate matter present
Yes iN') N/A b. Potential toxicity (dead fish, dead plant at discharge)
Yes No N/A 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%.
e

Page 5
28. Sampling:
�es No N/A a. Sampling and analysis completed on parameters specified by permit
Yes No N/A b. Composite sample temperatures maintained at 4 degrees Celsius or
less (but above freezing) during sampling
No N/A c. Contract laboratory used for sample analysis
.Y. No N/A d. Effluent composite samples obtained are flow proportional.
RECORDI:EEPING AND REPORTING
qes No N/A 1. Records and reports maintained as required by permit.
Yes INo N/A 2. All required information available, complete, and current.
(Ye�No N/A 3. Records maintained for 3 years and all sludge records maintained for 5
years.
No N/A 4. Analytical results consistent with data reported on DMiRs.
5. Sampling and analyses data adequate and include:
'S) No N/A a. Dates, times, and location of sampling
es. No N/A b. Name of individual performing sampling
&D No N/A c. Results of analyses and calibration
'ems No N/A d. Dates of analyses
Ye No N/A e. Name of person performing analyses.
6. Monitoring records adequate and include:
Yes No N/A a: Monitoring charts kept for 3 years
es No N/A b. Flowmeter calibration records kept for 3 years.
es No N/A 7. The pH meter is calibrated daily with twa buffers and checked with a
third buffer and properly documented.
Yes No N/A 8. Expiration dates of pH buffers adequate.
Yes No N/A 9. All thermometers used in NPDES permit reporting is calibrated
annually with an NIST certified thermometer or a traceable
thermometer annually and documented.
Ye ) No N/A 10. The following NPDES permit required parameters are analyzed on site:
pH, Temperature, Dissolved Oxygen and Chlorine Residual.

Page 6
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
Yes No N/A
Yes No N/A
Yes No N/A
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.
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 15. Permittee is meeting compliance schedule.
No N/A 16. DMRs complete and include all NPDES permit required parameters.
es 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.
No N/A 18. ORC visitation logs available and current.
es No N/A 19. ORC certified at a level equal to or greater than the classification of
the wastewater facility.
Yew 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.
es No N/A 23. Facility analyzes process control parameters for example: IY]Z,SS,
MCRT, Settleable Solids and others that are applicable.
Yes No N7A� 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

INSPECTION REPORT
UPDATE OPTION: TRX: 5IF KEY: NC0005762INSCEI 011009
SYSMSG: *** DATA ADDED SUCCESSFULLY ***
PERMIT--- NC0005762 REG/COUNTY-- 06 SCOTLAND
FACILITY-- WESTPOINT STEVENS-WAGRAM LOC-- WAGRAM
INS TYPE
CEI
NEXT PLANNED
INSPECTION INSPECTED BY:
DATE m:. 01100.9 HSB
REI?ORT INSPECTION DMR RESPONSE RECEIVED
DATE STATUS STATUS. DUE DATE DATE
011.019 C C 011130
COMMENTS:

61,
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°'
WESTPOINT STEVENS
December 14, 2001
Ms. Belinda Henson
Environmental Chemist
North Carolina Department of Environment
and Natural Resources, Division of Water Quality
225 Green Street, Suite 714
Fayetteville, NC 28301-5043
RE: Compliance Evaluation Inspection
NPDES Permit No. NC0005762
WestPoint Stevens Inc., Scotland County
Dear Ms. Henson:
vArupcY-
IDED 1 1 2001
This letter :is,in response to your Compliancd`EValuation Inspection conducted on October 9, 2001.
We appreciate your thoroughness and have as in inspections in the past benefited from the comments
and recommendations.
In response to Item 1, Section D, an automatic, in -channel, Dontech bar screen has been ordered to
replace the existing bar screen. This bar screen is scheduled for delivery the week of December 17
and will be installed and fully operational in January.
If you have any questions or need additional information please call me at [phone].
Sincerely,
Yan D. Helton
copy: W..Adams
E. Lanier
T. Tarver
POST OFFICE BOX 388, WAGRAM, NORTH CAROLINA 28396 • AREA 910 369-2231