NC0035173_CEI_Letter_20240201

ROY COOPER
Governor
ELIZABETH S. BISER
Secretary
RICHARD E. ROGERS, JR.
Director
Wieland Copper Products, LLC
Attn: Ivan D. Stefano
3990 US 311 Hwy North
Pine Hall, NC 27042
SUBJECT: Compliance Evaluation Inspection
Wieland Copper Products, LLC
NPDES Permit NCO035173
Stokes County
Dear Mr. Stefano:
NORTH CAROLINA
Environmental Quality
February 1, 2024
Ron Boone, of the Winston-Salem Regional Office of the NC Division of Water Resources, conducted a compliance
evaluation inspection of the Wieland Copper Products, LLC wastewater treatment facility, which is permitted to discharge
treated wastewater via outfall 001 to the Dan River in accordance with the NPDES discharge permit NC0035173. The
inspection was conducted on January 29th, 2024. Operator in responsible charge, ORC, Cliff Cain, EHS Manager, Tony
Sprinkle, and EHS Coordinator, Thomas Ford were all present for the inspection.
Inspection findings are detailed on the attached Water Compliance Inspection Report. The facility was found to be
compliant with NPDES discharge permit NC0035173.
Thank you for your time and efforts in facilitating the inspection. Please feel free to contact Mr. Boone directly by phone
at 336-776-9690, or by email at [e-mail], if you have any questions regarding the inspection or this report.
Sincerely,
DocuSigned by:
OD2D3CE3F161456...
Jennifer F. Graznak, Assistant Regional Supervisor
Water Quality Regional Operations Section
Winston-Salem Regional Office
Division of Water Resources, NCDEQ
Attachments:
Water Compliance Inspection Report
cc: Tony Sprinkle, EHS Manager, via email
Cliff Cain, Operator in Responsible Charge, via email
D Q
25 North Carolina Department of Environmental Quality I Division of Water Resources
Winston-Salem Regional Office 1 450 W. Hanes Mill Rd, Suite 300 I Winston-Salem, North Carolina 27105
NORTH CARCLINq
336.776.9800

United States Environmental Protection Agency
Form Approved.
EPA Washington, D.C. 20460
OMB No. 2040-0057
Water Compliance Inspection Report
Approval expires 8-31-98
Section A: National Data System Coding (i.e., PCS)
Transaction Code NPDES yr/mo/day Inspection Type Inspector Fac Type
1 IN 1 2 u 3 I NCO035173 I11 121 23/01/29 I17 18I � I 19 I s I 20L]
21111I I I I I I I II I I I I I I I I I I I I I I I I I I I I I I I II I I I I I r6
Inspection
Work Days Facility Self -Monitoring Evaluation Rating B1 QA ---------------------- Reserved -------------------
67
I 72 I ni I 71 I 74 79 I I I I I I I80
701 I 71 I LL -1 I I
LJ
Section B: Facility Data
Name and Location of Facility Inspected (For Industrial Users discharging to POTW, also include
Entry Time/Date
Permit Effective Date
POTW name and NPDES Dermit Number)
11:10AM 23/01/29
22/03/01
Wieland Copper Products, LLC
3990 US 311 Hwy N
Exit Time/Date
Permit Expiration Date
Pine Hall NC 27042
01:05PM 23/01/29
22/10/31
Name(s) of Onsite Representative(s)/Titles(s)/Phone and Fax Number(s)
Other Facility Data
Clifford Curtis Cain/ORC/336-996-2841/
Name, Address of Responsible Official/Title/Phone and Fax Number
Contacted
Tony Ryan Sprinkle,3990 US 311 Hwy N Pine Hall NC 27042/Safety & Environmental
Supervisor/336-445-4526/ No
Section C: Areas Evaluated During Inspection (Check only those areas evaluated)
Permit 0 Flow Measurement Operations & Maintenar Records/Reports
Self -Monitoring Progran 0 Sludge Handling Dispo: Facility Site Review Effluent/Receiving Wate
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
Ron Boone Docusigned by: DWR/WSRO WQ/336-776-9690/
Ostia& Boone, 2/1/2024
B20FSDD5F2A3460...
Signature of Management Q A Reviewer Agency/Office/Phone and Fax Numbers Date
DwR/wslto 336-776-9695
FjDocuSigned by: 2/1/2024
'—OD2D3CE3F 1 B7456_.
EPA Form 3560-3 (Rev 9-94) Previous editions are obsolete.
Page#

NPDES yr/mo/day Inspection Type
NCO035173 I11 12I 23/01 /29 117 18 i c i
(Cont.)
Section D: Summary of Finding/Comments (Attach additional sheets of narrative and checklists as necessary)
Ron Boone, of the Winston-Salem Regional Office of the NC Division of Water Resources, conducted
a compliance evaluation inspection of the Wieland Copper Products, LLC wastewater treatment
facility, which is permitted to discharge treated wastewater via outfall 001 to the Dan River in
accordance with the NPDES discharge permit NC0035173. The inspection was conducted on January
29th, 2024. Operator in responsible charge, ORC, Cliff Cain, EHS Manager, Tony Sprinkle, and EHS
Coordinator, Thomas Ford were all present for the inspection.
The inspection consisted of a field portion, in which the biological and physical/chemical wastewater
treatment processes were inspected, and then an administrative portion where records of operation,
maintenance, laboratory monitoring and discharge monitoring reports were reviewed.
Field Portion
The plant consists of two major parts, as follows:
1. Biological wastewater treatment process: This process receives all wastewater from the
manufacturing facility including all domestic wastewater from bathroom, kitchen, and office facilities in
the plant, as well as all industrial wastewaters. This plant consists of a bar screen, activated sludge
extended diffused aeration basin, clarifier, manual pH and/or alkalinity control, chlorination,
dechlorination, effluent pump station, and aerobic sludge digestion. This part of the process
appeared to be operating well. The mixed liquor in the aeration basin appeared and smelled healthy.
The clarifier was operating well with good separation, skimming, and a clear overflow mostly free of
solids carryover. The weirs appeared level and no short-circuiting was detected. Two chlorination and
two dechlorination tubes were in use at the time of the inspection and all four had a sufficient supply
of tablets in them. The aerobic digestor is emptied about twice per year according to Mr. Cain, and
sludge removal records were available for review. This plant appeared clean and well maintained.
2. Physical/chemical treatment process: This process receives the effluent from the biological
wastewater treatment process, and its primary purpose is to remove copper from the wastewater.
This process consists of the following components: a coagulation, flocculation, and fabric filter bed
component removes larger solids to prevent fouling of the next downstream process, which is copper
removal via ion exchange. The wastewater flow is then measured using a factory -calibrated Toshiba
in -line electromagnetic flow meter and discharged to an unnamed tributary of the Dan River. This
process also appeared to be operating well. No issues were noted, and the plant was very clean and
well maintained.
For the most part, the field portion of the inspection revealed that the system is compliant. Mr. Boone
did note, however, that several areas of the biological treatment system structure are severely
corroded, some to the point of possible failure. This can also present a severe safety hazard for
operators and maintenance personnel by exposing them to the jagged edges of corroded metal. A
large part of the structure, but not all of it, was recently painted and appears to be in good condition
for its age. But the unpainted portions indicate severe corrosion. All areas of severe corrosion should
be repaired, and steps taken to eliminate or impede the corrosion in the future.
Administrative Portion
Mr. Boone reviewed discharge monitoring reports (DMR), laboratory results, field sheets, chains of
custody, operation and maintenance records, the spill plan, the operator visitation log, and sludge
removal records. All reviewed records were complete and well kept. No errors or violations were
noted. Laboratory data and DMRs for January, June, and November 2023 were reviewed and no
errors were noted. Wieland uses Pace Laboratories, certificate #633, for both field and non -field
parameter monitoring.
Page#

Permit: NCO035173
Inspection Date: 01/29/2023
Owner - Facility: Wieland Copper Products, LLC
Inspection Type: Compliance Evaluation
Altogether, Mr. Boone found Wieland to be compliant with permit NC0035173. Thank you for your
time and efforts in facilitating the inspection. Please feel free to contact Mr. Boone directly by phone
at 336-776-9690, or by email at [e-mail].
Page#

Permit: NCO035173 Owner - Facility: Wieland Copper Products, LLC
Inspection Date: 01/29/2023 Inspection Type: Compliance Evaluation
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?
❑
■
❑
❑
# Are there any special conditions for the permit?
❑
■
❑
❑
Is access to the plant site restricted to the general public?
■
❑
❑
❑
Is the inspector granted access to all areas for inspection?
■
❑
❑
❑
Comment: There is no flow meter in use on the biological side of the plant.
Record Keeping
Yes
No
NA
NE
Are records kept and maintained as required by the permit?
■
❑
❑
❑
Is all required information readily available, complete and current?
■
❑
❑
❑
Are all records maintained for 3 years (lab. reg. required 5 years)?
■
❑
❑
❑
Are analytical results consistent with data reported on DMRs?
■
❑
❑
❑
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
■
Name of person performing analyses
■
Transported COCs
■
Are DMRs complete: do they include all permit parameters?
■
❑
❑
❑
Has the facility submitted its annual compliance report to users and DWQ?
❑
❑
■
❑
(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: Spill plan, O&M log, sludge removal records, NOVs all on file on site.
Laboratory Yes No NA NE
Are field parameters performed by certified personnel or laboratory? ■ ❑ ❑ ❑
Page# 4

Permit: NCO035173 Owner - Facility: Wieland Copper Products, LLC
Inspection Date: 01/29/2023 Inspection Type: Compliance Evaluation
Laboratory Yes No NA NE
Are all other parameters(excluding field parameters) performed by a certified lab?
0
❑
❑
❑
# Is the facility using a contract lab?
■
❑
❑
❑
# Is proper temperature set for sample storage (kept at less than or equal to 6.0
❑
❑
❑
degrees Celsius)?
Incubator (Fecal Coliform) set to 44.5 degrees Celsius+/- 0.2 degrees?
❑
❑
0
❑
Incubator (BOD) set to 20.0 degrees Celsius +/- 1.0 degrees?
❑
❑
0
❑
Comment: All monitoring requires grab samples except for quarterly toxicity. Facility
uses Pace
labs certificate #633. Reviewed labs and DMRs for January, July, and November 2022.
No errors noted.
Effluent Sampling
Is composite sampling flow proportional?
Is sample collected below all treatment units?
Is proper volume collected?
Is the tubing clean?
# Is proper temperature set for sample storage (kept at less than or equal to 6.0
degrees Celsius)?
Is the facility sampling performed as required by the permit (frequency, sampling type
representative)?
Comment: All monitoring requires grab samples except for quarterly toxicity.
Yes No NA NE
❑ ❑ ■ ❑
■ ❑ ❑ ❑
■ ❑ ❑ ❑
❑ ❑ ■ ❑
❑ ❑ ❑ ■
■ ❑ ❑ ❑
Upstream / Downstream Sampling Yes No NA NE
Is the facility sampling performed as required by the permit (frequency, sampling type, 0 ❑ ❑ ❑
and sampling location)?
Comment: None
Bar Screens
Yes
No
NA
NE
Type of bar screen
a.Manual
b.Mechanical
❑
Are the bars adequately screening debris?
0
❑
❑
❑
Is the screen free of excessive debris?
■
❑
❑
❑
Is disposal of screening in compliance?
■
❑
❑
❑
Is the unit in good condition?
0
❑
❑
❑
Comment: None
Page# 5

Permit: NCO035173
Inspection Date: 01/29/2023
Bar Screens
Owner - Facility: Wieland Copper Products, LLC
Inspection Type: Compliance Evaluation
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'/4 of the sidewall depth)
Yes No NA NE
Yes
No
NA
NE
■
❑
❑
❑
❑
❑
■
❑
■
❑
❑
❑
■
❑
❑
❑
■
❑
❑
❑
■
❑
❑
❑
■
❑
❑
❑
❑
❑
■
❑
■
❑
❑
❑
■
❑
❑
❑
❑
❑
❑
■
Comment: Much and the plant was just recently painted and looks excellent. However, the
structure is beginning to corrode badly in many
areas and could fail if left unrepaired.
Wieland should begin thinking about repairing
all such areas of the structure.
Pumps-RAS-WAS
Yes
No
NA
NE
Are pumps in place?
0
❑
❑
❑
Are pumps operational?
■
❑
❑
❑
Are there adequate spare parts and supplies on site?
E
❑
❑
❑
Comment: None
Aeration Basins
Mode of operation
Type of aeration system
Is the basin free of dead spots?
Are surface aerators and mixers operational?
Are the diffusers operational?
Is the foam the proper color for the treatment process?
Does the foam cover less than 25% of the basin's surface?
Is the DO level acceptable?
Is the DO level acceptable?(1.0 to 3.0 mg/1)
Yes No NA NE
Ext. Air
Diffused
■
❑
❑
❑
❑
❑
■
❑
■
❑
❑
❑
■
❑
❑
❑
■
❑
❑
❑
❑
❑
❑
■
❑
❑
❑
■
Page# 6

Permit: NC0035173
Inspection Date: 01/29/2023
Aeration Basins
Owner - Facility: Wieland Copper Products, LLC
Inspection Type: Compliance Evaluation
Yes No NA NE
Comment: Much and the plant was lust recently painted and looks excellent. However, the
structure is beginning to corrode badly in many
areas and could fail if left unrepaired.
Wieland should begin thinking about repairing
all such areas of the structure. Mixed
liquor looks and smells healthy.
Disinfection -Tablet
Yes No
NA
NE
Are tablet chlorinators operational?
0 ❑
❑
❑
Are the tablets the proper size and type?
0 ❑
❑
❑
Number of tubes in use? 2
Is the level of chlorine residual acceptable? ❑ ❑ ❑
Is the contact chamber free of growth, or sludge buildup? ■ ❑ ❑ ❑
Is there chlorine residual prior to de -chlorination? ❑ ❑ ❑
Comment: None
De -chlorination
Yes
No
NA
NE
Type of system ?
Tablet
Is the feed ratio proportional to chlorine amount (1 to 1)?
❑
0
❑
❑
Is storage appropriate for cylinders?
❑
❑
❑
# Is de -chlorination substance stored away from chlorine containers?
0
❑
❑
❑
Are the tablets the proper size and type?
■
❑
❑
❑
Comment: None
Are tablet de -chlorinators operational?
■
❑
❑
❑
Number of tubes in use?
2
Comment: None
Flow Measurement - Effluent
Yes
No
NA NE
# Is flow meter used for reporting?
0
❑
❑
❑
Is flow meter calibrated annually?
❑
0
❑
❑
Is the flow meter operational?
0
❑
❑
❑
(If units are separated) Does the chart recorder match the flow meter?
0
❑
❑
❑
Comment: Meter is an inline mag meter that is not calibrated. It is replace if it
goes bad.
Effluent Pipe Yes No NA NE
Is right of way to the outfall properly maintained? 0 ❑ ❑ ❑
Page# 7

Permit: NCO035173
Inspection Date: 01/29/2023
Owner - Facility: Wieland Copper Products, LLC
Inspection Type: Compliance Evaluation
Effluent Pipe
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: None
Aerobic Digester
Is the capacity adequate?
Is the mixing adequate?
Is the site free of excessive foaming in the tank?
# Is the odor acceptable?
# Is tankage available for properly waste sludge?
Comment: Sludge removed about twice yearly. Removal records on hand.
Yes
No
NA
NE
■
❑
❑
❑
❑
❑
❑
Yes
No
NA
NE
❑
❑
❑
❑
❑
❑
❑
❑
❑
❑
❑
❑
❑
❑
❑
Operations & Maintenance Yes No NA NE
Is the plant generally clean with acceptable housekeeping? 0 ❑ ❑ ❑
Does the facility analyze process control parameters, for ex: MLSS, MCRT, Settleable 0 ❑ ❑ ❑
Solids, pH, DO, Sludge Judge, and other that are applicable?
Comment: None
Page# 8