NC0005762_Biomonitoring Inspection_20000911

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NORTH CAROLINA DEPARTMENT OF
ENVIRONMENT AND NATURAL RESOURCES
DIVISION OF WATER QUALITY
FAYETTEVILLE REGIONAL OFFICE
September 11, 2000
Mr. Yancy Helton
West Point Stevens, Inc. (formerly J.P. Stevens-Wagram)
P.O. Box 388
Wagram, NC 28396
Subject: COMPLIANCE BIOMONITORING INSPECTION
West Point Stevens, Inc. (J. P. Stevens - Wagram WWTP)
NPDES Permit No. NC0005762
Scotland County
Dear Mr.dielton:
Enclosed you will find a copy of the Compliance Biomonitoring Inspection
report for the inspection conducted the week of August 7, 2000. The inspection
included the same objectives as that of a routine Compliance Evaluation Inspection
(conducted. on August 8, 2000) plus an Aquatic Toxicity (AT) test to evaluate the
biological effect of the facility's discharge on test organisms. The results of the
chronic Ceriodaphnia dubia pass/fail toxicity test was recorded as a "Pass". 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. Aliquots of the 24-hour effluent composite sample
(collected from August 7 to August 8), were analyzed for the following parameters,
which are currently in you NPDES Permit: five-day biochemical oxygen demand,
chemical oxygen demand, total suspended solids, sulfides, phenols, chromium,
nickel, copper, and zinc. The results of these parameters will be forwarded to you
when they are completed by the Division of Water Quality Chemistry Laboratory,
located on Reedy Creek Road in Raleigh.
It is a priority to discharge a good quality effluent that will not pose any
problems to the receiving stream and ensure complete compliance with the NPDES
permit.
225 GREEN STREET, SUITE 714 / SYSTEL BLD. FAYETTEVILLE, NORTH CAROLINA 28301-5043
PHONE [phone] FAX [phone]
AN EQUAL OPPORTUNITY / AFFIRMATIVE ACTION EMPLOYER - 50% RECYCLED/10% POST -CONSUMER PAPER

If you have any questions or comments concerning this report or require
clarification on part(s) of this report, please feel free to contact me at 910/486-1541,
ext. 340.
Dale Lopez
Environmental Speci fist II
DL/dl
Enclosures
cc: DWQ, ESB, ATU, Kevin Bowden
DWQ Laboratory Certification Unit

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: 000808 Inspection Type: B
Inspector: S Facility Type: 2 Reserved:
Facility Evaluation Rating: 4 BI: D QA: N Reserved:
Section B: Facility Data
Name and Location of Facility Inspected:
West Point Stevens, Inc. WWTP
Entry Time/Date: 9:00 AM/000808 Permit Effective Date: 940901
Exit Time/Date:
2:30 PM/000808 Permit Expiration Date: 990831
(The permit renewal is in Raleigh)
Name(s), Title(s) of On -Site Representative(s):
Herman Benton (Certified Grade IV) - ORC
Gerorge Brown (Certified Grade IV) — Backup Operator
John Graham (Certified Grade IV)
Bill Locklear — Maintenance Mechanic
Phone Number(s): [phone]
Name, Title and Address of Responsible Official:
Mr. Yancy Helton
P. O. 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: ,S
Records/Reports: 'S
Facility Site Review:
Flow Measurement: 'S
Laboratory:.: S.
"Pretreatment: N
Self -Monitoring Program: S
Effluent/Receiving Waters:.S
Coinpliance'Schediile:- N/A
Operation &;Maintenance:S

West Point Stevens, Inc. WWTP
BIOMONITORING EVALUATION INSPECTION performed on August 7, 2000
Contact personnel:
Herman Benton (Certified Grade IV) --- ORC
George Brown (Certified Grade IV) --- Backup ORC
DESCRIPTION OF West Point Stevens, Inc. WWTP:
7.0 MGD wastewater treatment facility consisting of an automatic bar screen, mixing chamber, two influent
screw pumps, influent Parshall flume (one foot) and ultrasonic flow meter, 10 million gallon capacity
equalization basin, six million gallon capacity aeration basin with twelve aerators (six are 75 HP, and six are
60 HP) and two mixers, a slow mix and a flash mix polymer addition tank, three clarifiers (ninety feet in
diameter), defoamer is added at the reaeration basin, effluent Parshall flume (2 feet) and ultrasonic flow
meter, ''A mile of ditch to the Lumber River. Sludge is processed by a gravity belt thickener, sludge belt
press and 1.2 million gallon capacity aerobic sludge digester, then trucked to farm.
SECTION D: SUMMARY OF FINDINGS/COMMENTS:
PLANT TOUR---
1. The effluent ultrasonic flowmeter was calibrated on August 10, 2000 and no adjustments were
necessary.
2. #1 secondary clarifier was down for maintenance.
3. For process control the 30 minute settleometer test is performed, the MLTSS target is 2100
mg/L, the F/M ratio using COD as the food in the calculation is 0.3 to 0.4.
4. The effluent composite refrigerator temperature was observed to be 0.5 degrees Centigrade,
which agrees with the official interpretation of the storage temperature requirement published
in 40 CFR Part 136.3 (e), Table II (the acceptable temperature range is 0-4 degrees Centigrade).
At West Point Stevens, air-conditioned and insulated housing of the refrigerator helps to
achieve this temperature requirement, even during the summer months.
5.
Clarifier #
Depth
1
Out of Service for painting
2
1.5 feet at middle
3
1.5 feet at middle
6. The effluent outfall discharge line was not easily accessible.
7. Many plastic teeth on the mechanical bar screen were broken, possibly caused in part by
influent temperatures that were in the 24 to 39 degree Centigrade range.

LABORATORY TOUR---
1. A three point calibration is performed five days per week with a pH Orion Model 420A. The
millivolt reading for the 7 pH buffer was —20.6. The upstream and downstream pH is
performed Orion Model 250A.
2.
PH Buffer
Expiration Date
4.0
September 2001
7.0
November .2001
10.0
September 2001
3. Dissolved Oxygen is performed by a YSI Model 57 bench meter and a YSI Model 55 portable
unit.
4. Temperatures are taken with a YSI Model 55 portable. It is cross-checked with a NIST
traceable thermometer.
5. Chlorine is performed with a HACH DR 4000 using the 25 mL DPD powder pillows.
6. Barnstead E-Pure deionized water is used for dilution water (>16.6 megohms). Three Polyseed
tablets are diluted with 80 mL of this water for two hours of mixing. Then 100 mL are
dispensed into eight bottles and then frozen. When needed this seed is defrosted in a 25 degree
Centigrade waterbath. 3 mL are used for each BOD bottle (for -a 1% seed per bottle). The
GGA is prepared from Dextrose and Glutamic Acid once per month and is kept refrigerated.
7.' Temperature measurements are performed with NIST checked disposable thermometers for the
BOD incubator, the TSS drying oven, the laboratory refrigerator (Fischer Catalog #: 15-171-2
for the —5 to 15 C range), the influent sampler, and the effluent sampler.
8 The Sartorius Basic analytical balance was calibrated on 09/02/99 by a Sartorius Technician.
9 Color analysis is performed by scanning the 350 to 750 nanometer range with an automatic
scanning spectrophotometer and comparing to a computer programmed scale, which was
calibrated from four dilutions (50, 125, 250, and 500) of a 500 unit Platinum Cobalt Color
Standard purchased from HACH.

RECOMMENDATIONS---
1. Recommend that an ORC visitation log be used, as stated in 15A NCAC 8G .0204
RESPONSIBILITIES OF AN OPERATOR IN RESPONSIBLE CHARGE (5):
"document the operation, maintenance, and all visitation o_ f the system in a daily log that shall
be maintained at the system".
2. Recommend that the location of the final effluent discharge line be marked at the roadside and
thus bemade more easily accessible.
Name and Signature of Inspector
Agency/Office/Telephone Date
Dirt opez % NCDENR/ Fayetteville/ [phone] i // 5
Name and Signature of Rewer Agency/Office/Telephone Date
i
Belinda S. Henson f '..uc e � t .tc - �o NCDENR/ Fayetteville/ [phone] C / I `l l 0
Action Taken
Regulatory Office Use Only
Compliance Status
_Noncompliance
_Compliance
Date

r
r
/ .E2//nt/l /' /,1 L'•7
Section D: Summary of Findings/Comments
Brief Facility Description:
FACILITY SITE REVIEW
Yes No N/A 1. Treatment units properly operated and maintained.
Yes To) N/A 2. Standby power or other equivalent provision provided.
C!'\s 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
No N/A b. State approval for sludge disposal received.
es No N/A 5. All treatment units other than backup units in service. Cli'u;-y fl /Ltts7 e2-1
sNo N/A 6. Sufficient sludge disposed of to maintain treatment process equilibrium.
(-)No N/A 7. Adequate number of qualified operators on staff.
Ce-;) No N/A 8. Established procedures available for training new employees.
✓j No N/A 9. Adequate spare parts and supplies inventory maintained.
No N/A 10. a. Hydraulic overflows and/or organic overloads experienced
No N/A b. Untreated bypass discharge occurs during power failure
es) No N/A c. Untreated overflows occurred since last inspection.
Yes
N/A 11. Plant has general safety structures such as rails around or covers over
tanks, pits, or wells.
f,_,No N/A 12. Plant is generally clean, free from open trash areas.

Yes No (NJ
es No N/A
Yes S N/A
e� No N/A
Yes No
Yes No
Yes No
Yes No
Yes No
Yes No
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
N/A
N/A
N/A
Page 2
13. Screening: / Z CIlrn.@aiL. L t f� �',�",,
a. Manual /)h- LLB. %Zirli /✓LCll't ...40-1.217`l k "L2..
b. Mechanical :4 .ezze-11t ,/,iy ,y_iLrtel + A V 4 :3 `C :?,;;fe
c. Buildup of debris 1
d. Screenings properly disposed of.
14. Grit Removal:
a. Excessive organic content in the grit chamber
b. Excessive odors
c. Grit properly disposed of.
15. 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.
16. Trickling Filter:
Yes No' a. Trickling filter ponding(indicating clogged media)
Yes No N/A b. Leak at center column of trickling filter's distribution arms
Yes No N/A c. Uneven distribution of flow on trickling filter surface
Yes No N/A d. Uneven or discolored growth
Yes No N/A e. Excessive sloughing of growth
Yes No N/A f. Odor
Yes No N/A g. Clogging of trickling filter's distribution arm orifices
Yes No \N/A 7 h. Filter flies, worms, or snails..
17. Rotating Biological Contactors (RBC):
Yes No f N/A "' a. Development of white biomass on rotating biological contactor
media
Yes No N/A b. Excessive sloughing of growth
Yes No N/A c. Excessive breakage of rotating disks or shafts in RBC units
Yes No N/A d. Excessive breakage of paddles on brush aerators
Yes No \N/AJ e. Shaft, bearing, drive gear, or motor failure on disk or brush aerators.

Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes No
Yes No
Yes No
Yes No
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
Page 3
18. (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.
19. 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.
20. Secondary Clarifier:
Yes o N/A a. Excessive gas bubbles on surfacf3
Yes N/A b. Unlevel overflow weirs
Yes N/A c. Weir blockage
Yes N/A d. Evidence of short circuiting
Yes o N/A e. Excessive buildup of solids in center well of circular clarifier
Yes o: N/A f. Pin floc in overflow
Yes N/A g. Ineffective scum rake
Yes N/A h. Floating sludge on surface
Yes o) N/A i. Excessive high sludge blanket
Yes o N/A j. Clogged sludge withdrawal ports on secondary clarifier.
Yes No
Yes No
Yes No
Yes No
Yes No
Yes No
Yes No
Yes No
Yes No
Yes No
Yes No
Yes No
Yes No
Yes No
N/
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
/A
0,124.t:bt . � 6..�'.IL4 '=
21. 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 in excess of 5 percent
f. Formation of mudballs in filter media.
22. 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
Yes No (N/A) 23. Ultraviolet radiation disinfection present and in use.
Yes No
Yes No
Yes No
Page 4
24. Dechlorination:
a. Proper storage of sulfur dioxide cylinders
b. Adequate ventilation of sulfur dioxide feeding room
c. Automatic sulfur dioxide feed or feedback control not operating
properly.
25. Aerobic Digester:
Yes ' N/A a. Excessive foaming in tank
Yes j N/A b. Noxious odor
No N/A c. Mechanical aeration failure
No /A d. Clogging of diffusers.
26. Anaerobic Digester:
Yes No N/A\ . a. Floating cover tilting
Yes No N/A b. Gas burner operative
Yes No N/A 1 c. Supernatant has a sour odor.
27. Sludge Drying and/or disposal:
Yes No N/Aa. Poor sludge distribution on drying beds
Yes No N/A ` b. Vegetation in drying beds
Yes No N/A , c. Dry sludge remaining in drying beds
Yes No N/A 1 d. Dry sludge stored on site
Yes No N/A e. Filtrate from sludge drying beds returned to front of plant
Yes No N/A f. Approved disposal site for the sludge
Yes No /A g. Sludge land applied.
28. Filter Press:
Yes N/A a. High level of solids in filtrate from filter presses or vacuum filters
Yes o) N/A b. Thin filter cake caused by poor dewatering
Yes o) N/A c. Sludge buildup on belts and/or rollers of filter press
Yes o j N/A d. Excessive moisture in belt filter press sludge cake.
Yes No
Yes No
Yes No
29. Polishing Pond 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.

Page 5
30. Plant Effluent:
Yes T�' N/A a. Excessive suspended solids, turbidity, foam, grease, scum, color, and
other macroscopic particulate matter present
Yes N/A b. Potential toxicity (dead fish, dead plant at discharge)
Yes �) N/A c. Outfall discharge line easily accessible.
No N/A
No N/A
N/A
N/A
No N/A
'es No
Yes No
es No
5 No
N/A
N/A
31. 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. Properly functioning magnetic flowmeter
f. Clogged or broken stilling wells
g. Weir plate edge corroded or damaged
h. System capable of measuring maximum flow
i. Flow measurement error less than 10%.
32. Sampling:
No N/A a. Sampling and analysis completed on parameters specified by permit
No N/A b. Samples refrigerated during compositing
e§i No N/A c. Composite sample temperatures maintained at 0 to 4 degrees Celsius
during sampling
No N/A d. Contract laboratory used for sample analysis
5 No N/A e. Composite samples obtained are flow proportional.
RECORDKEEPING AND REPORTING
re., No N/A 1. Records and reports maintained as required by permit.
SNo N/A 2. All required information available, complete, and current.
es� No N/A 3. Records maintained for 3 years and all sludge records maintained for 5
years.
es) No N/A 4. Analytical results consistent with data reported on DMRs.
5. Sampling and analyses data adequate and include:
es) No N/A a. Dates, times, and location of sampling
es-' No N/A b. Name of individual performing sampling
) No N/A c. Results of analyses and calibration
es,} No N/A d. Dates of analyses
e No N/A e. Name of person performing analyses.

Page 6
6. Monitoring records adequate and include:
e 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. Laboratory equipment calibration and maintenance records adequate.
Yes No N/A 8. BOD incubator temperature maintained at 20 +/- 1 Degrees Celsius
and the temperature maintained in a log for every day of operation.
Yes No
No N/A
No N/A
s No N/A
Yes No N/A
9. Fecal coliform incubator maintained at 44.5 +/- 0.2 Degrees
Celsius and the temperature maintained in a log for every, day of
operation.
10. Plant records adequate and include:
a. 0 & M Manual
b. "As -built" engineering drawings
c. Schedules and dates of equipment maintenance repairs
d. Equipment data cards.
Yes No /N/ 11. Permittee is meeting compliance schedule.
e j No N/A 12. DMRs complete and include all NPDES permit required parameters.
Yes �� No) N/A 13. ORC visitation logs available and current.
No N/A
No N/A
es) No . N/A
Yes No N/A
Revised 7/11/00
by Belinda Henson
14. ORC certified at a level equal to or greater than the classification of
the wastewater facility.
15. Backup Operator certified at one level less than the classification of
the wastewater facility or greater.
16. Current copy of the complete NPDES permit on site.
17. Facility description verified as contained in NPDES permit.

INSPECTION REPORT
UPDATE OPTION: TRX: 5IF KEY: NC0005762INSBIO 000807
SYSMSG: *** DATA ADDED SUCCESSFULLY ***
PERMIT--- NC0005762
REG/COUNTY-- 06 SCOTLAND
FACILITY-- WESTPOINT STEVENS, INC. LOC-- WAGRAM
INS TYPE
BIO
NEXT PLANNED
INSPECTION INSPECTED BY:
DATE: 000807 LD
REPORT INSPECTION DMR RESPONSE RECEIVED
DATE ,STATUS STATUS DUE DATE DATE
000911 C - C
COMMENTS: