NC0002305_Compliance Evaluation Inspection_20241115

Docusign Envelope ID: EE9C06CF-D83D-4CCF-86CE-A3C23FOAD3DO
SrAIr
ROY COOPER _
Governor
MARY PENNY KELLEY
Secretary
RICHARD E.ROGERS,JR. NORTH CAROLINA
Director Environmental Quality
November 20, 2024
Michael Cothran
Lear Corporation
1754 NC Highway 903
Kenansville, NC 28349
SUBJECT: Compliance Inspection Report
Lear Corporation WWTP
NPDES WW Permit No. NC0002305
Duplin County
Dear Permittee:
The North Carolina Division of Water Resources conducted an inspection of the Lear Corporation WWTP
on 11/15/2024. This inspection was conducted to verify that the facility is operating in compliance with
the conditions and limitations specified in NPDES WW Permit No. NC0002305. The findings and
comments noted during this inspection are provided in the enclosed copy of the inspection report
entitled "Compliance Inspection Report".
Please respond in writing to this office within 30 days of your receipt of this letter regarding your plans
or measures to be taken to address the missing boards and handrails which were noted along the catwalk over
the effluent pipe to the river. It is also recommended that the system install secondary containment for the
tote containing de-foaming agents as well as the waste tanks present along the eastern side of the property.
Finally, it is recommended that the effluent composite sample line be re-routed to enable staff to inspect the
tubing along it's entire length to ensure it is clean and has no restrictions that would prevent proper samples
from being obtained.
If you should have any questions, please do not hesitate to contact Bryan Lievre with the Water
Quality Regional Operations Section in the Wilmington Regional Office at 910-796-7215 or via email at
[e-mail].
Sincerely,
DocuSigned by:
TOA.� �Aatrl�Oti
7F141E731361`3456...
Tom Tharrington, Assistant Regional Supervisor
Water Quality Regional Operations Section
Wilmington Regional Office
Division of Water Resources, NCDEQ
ATTACHMENT
Cc: George Yankay (via email)
Upload to Laserfiche
D North Carolina Department 1l:.mmental Quality l DWislon of Water Resources
Wilmington Regional on'ice 1127 Cardinal Drive Ulension I Wilmington,North Carolina 28405
910.79,7215

Docusign Envelope ID: EE9C06CF-D83D-4CCF-86CE-A3C23FOAD3DO
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 I 2 u 3 I NC0002305 I11 121 24/11/15 I17 18I�I 19 I G I 20U
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 70LJ 71Ity 72 L-J 73 1 74 79 I I I I 80
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 permit Number) 10:OOAM 24/11/15 18/10/01
Lear Corporation WWTP
1754 NC Hwy 903 N Exit Time/Date Permit Expiration Date
Kenansville NC 28349 02:OOPM 24/11/15 23/04/30
Name(s)of Onsite Representative(s)/Titles(s)/Phone and Fax Number(s) Other Facility Data
George R Yankay/ORC/910-296-5201/
Name,Address of Responsible Official/Title/Phone and Fax Number
Contacted
George Yankay, /ORC/910-296-5201/
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
Bryan Lievre Docusigned by, DWR/WIRO WQ/910-796-7215/
11/20/2024
E,? "4t
BAF550231BDD428...
Signature of Ma naEn
DSO&ebm ewer Agency/Office/Phone and Fax Numbers Date
Tom Tharringt 'AJWR/WIRO WO/ - - / 11/20/2024
EPA Form 3560-3(Rev 9-94)Previous editions are obsolete.
Page# 1

Docusign Envelope ID: EE9C06CF-D83D-4CCF-86CE-A3C23FOAD3D0
NPDES yr/mo/day Inspection Type (Cont.) 1
31 NC0002305 I11 12I 24/11/15 117 18 i c i
Section D: Summary of Finding/Comments (Attach additional sheets of narrative and checklists as necessary)
A routine compliance inspection of the Lear Corporation — Kenansville, Wastewater Treatment Plant
(WWTP), was performed on November 15, 2024. The purpose of the inspection was to verify that the
facility is operating in compliance with the conditions and limitations specified within Permit
NC0002305. Present during the inspection were Michael Cothran (Facility GM — intermittently
present), Jim Hurt (Plant EHS Manager), George Yankay (ORC), and Benjamin Boney (lab lead —
present for presentation of lab records)with Lear Corp as well as Doug Dowden, Fenton Brown,
Elaine Wild, Davis Conners, Lanny Le, Victoria Rivera-Mangual, Laura Oleniacz and Bryan Lievre, all
with NCDEQ.
Operations at the facility consist of warp knitting and weaving of synthetic fibers for the automotive
industry including dyeing, finishing, and flame lamination of knitted and woven synthetic fabrics. The
facility provides its own water with the operation of three water supply wells located on the property.
The wells are permitted within the Central Coastal Plan Capacity Use Area (CCPCUA) Water
Withdrawal (Permit#CU3094). Although the CCPCUA permit for the facility does not specify a limit for
the wells, the wells reportedly produced an average of 681,869 gallons per day (gpd)from 8/1/2023
through 7/31/2024. Well Number 1 also provides potable water for the facility and since the well is
privately owned, and provides water to at least 25 of the same people over six months per year, it is
classified as a non-transient non-community water system (NTNC)with NCDEQ and has been
assigned Public Water System ID #NC0431476. Available information indicates that the water supply
well produced an average potable daily flow of approximately 28,000 gpd in 2023.
The WWTP at the facility is classified as a Grade III Biological Water Pollution Control Treatment
System, permitted to receive up to 1.5 million gallons per day (mgd) of wastewater. The system has
had an average daily flow of approximately 0.60 mgd since 2015. Approximately 94% of the
wastewater is generated from the finished textile plant and the remaining wastewater is from water
softener backwash of the water treatment system and domestic waste from the facility's restrooms.
The WWTP has the following structures:
- Headworks with mechanical barscreen and Parshall Flume with liquid level sensor
- One 2 MG equalization basin with two floating aerators, one mixer and two transfer pumps
- One 2 MG aeration basin with 11 floating aerators
- A splitter box
- Two 55 feet diameter secondary clarifiers with RAS &WAS transfer pumps
- A sub-grade vault with (inoperative) in-line flash mixer
- One 60 feet diameter tertiary clarifier with solids removal pump
- 0.5 MG Chlorine contact tank (w/ 15% sodium hypochlorite solution)
- Dechlorination injection system (w/40% sodium bisulfite solution)
- Effluent flow meter and composite sampler
- Sludge/solids system with:
0 50,000 gal Sludge Thickener Tank
o One 1 MG sludge digester with 4 floating aerators, 1 mixer and transfer pump
o One 500,000 gal sludge tank with floating aerator
o One 50,000 gal filtrate tank with transfer pump
o A sludge drum thickener(inoperative)
o Eight (from twelve) sand sludge-drying beds with liquid recovery pumps
Page# 2

Docusign Envelope ID: EE9C06CF-D83D-4CCF-86CE-A3C23FOAD3DO
Permit: NC0002305 Owner-Facility: Lear Corporation WWTP
Inspection Date: 11/15/2024 Inspection Type: Compliance Evaluation
A review of monitoring records indicates that, since the last compliance inspection of 5/25/2022, the
system had three violations for toxicity limit exceedances resulting from sampling events performed
on 1/9/23 (NOV-2023-TX-0017), 2/13/2023 (NOV-2023-TX-0024), and 7/17/23 (NOV-2023-TX-0056).
Over the same period,DWR staff have responded to two complaints at the facility. The complaints
were in regards to the presence of more than trace amounts of foam in the receiving water at Outfall
001 and a potential crack in a wastewater tank. DWR staff responded to the complaint of foam on
9/2/2022 and to the potential crack in the tank on 4/23/24. The system responded to both incidents
with correspondence to document measures to be taken to prevent the recurrence of foam and a
plan to address the condition of the tank in the near future.
Since the last inspection, the facility has removed sludge from the equalization basin and clarifiers
and had a baffle system installed within the chlorine contact tank to increase retention time. The
facility has also purchased and installed a composite sampler and removed partition walls between
some of the sand drying beds to enable easier cleaning of solids from the structures.
The operator was very knowledgeable of the facility and the facility seemed to be well maintained,
although constant upkeep is required to deal with significant sludge buildup. Records were reviewed
and found to be detailed, well organized and complete. The facility is compliant with the terms and
conditions of the permit. Please review the comment sections of the inspection report for more
details.
Page# 3

Docusign Envelope ID: EE9C06CF-D83D-4CCF-86CE-A3C23FOAD3DO
Permit: NC0002305 Owner-Facility: Lear Corporation WWTP
Inspection Date: 11/15/2024 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: The last permit was issued 8/16/2018 and expired 4/30/2023; however, the permit has
been administratively extended since the system has submitted a permit renewal
application. For numerous reasons, including responses to public and EPA input, the
permit has not vet been renewed; although a draft permit was recently issued
11/6/2024. Special conditions of the draft permit include sampling the WWTF effluent,
upstream and downstream as well as groundwater wells at the site for PFAS
compounds, monthly sampling of the WWTF effluent for chronic toxicity, notification if
production exceeds 92,350 Ibs/year, annual Effluent Pollutant Scans in 2026, 2027
and 2028, as well as other changes.
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? ■ ❑ ❑ ❑
Page# 4

Docusign Envelope ID: EE9C06CF-D83D-4CCF-86CE-A3C23FOAD3DO
Permit: NC0002305 Owner-Facility: Lear Corporation WWTP
Inspection Date: 11/15/2024 Inspection Type: Compliance Evaluation
Record Keeping Yes No NA NE
Facility has copy of previous year's Annual Report on file for review? ❑ ❑ 0 ❑
Comment: On-line DMRs as well as select printed DMRs were viewed prior to and during the
inspection, respectively. Detailed operation and maintenance activities are logged on
a computer daily and additional information is entered into a spreadsheet for
comparison. George Yankay is a contract ORC with a WW-4 certification (#11710) and
Graham Johnson is the BORC with a WW-2 certification (#1013695).
Laboratory Yes No NA NE
Are field parameters performed by certified personnel or laboratory? 0 ❑ ❑ ❑
Are all other parameters(excluding field parameters) performed by a certified lab? ■ ❑ ❑ ❑
# Is the facility using a contract lab? 0 ❑ ❑ ❑
# Is proper temperature set for sample storage (kept at less than or equal to 6.0 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? ❑ ❑ ■ ❑
Comment: Lear Corp WWTP Laboratory is certified for analysis of field parameters (i.e., TRC,
conductivity, PH, temperature, DO)with Certification #5796. All required equipment
calibration logs and bench sheets were found to be comprehensive and complete.
Although the ORC obtains all the samples, the other analyses are delivered to
Environmental Chemists, Inc., except for acute toxicity which is performed by ETS Labs.
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 ❑ ❑ ❑
Solids, pH, DO, Sludge Judge, and other that are applicable?
Comment: Due to the nature of the wastewater, the operator relies on visual cues such as color,
foam and thickness of the wastewater in the aeration basin for process control. The
operators also take daily sludge thickness measurements and perform settleometer
tests. The information is recorded on various log sheets.
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? 0 ❑ ❑ ❑
Is disposal of screening in compliance? 0 ❑ ❑ ❑
Is the unit in good condition? 0 ❑ ❑ ❑
Page# 5

Docusign Envelope ID: EE9C06CF-D83D-4CCF-86CE-A3C23FOAD3D0
Permit: NC0002305 Owner-Facility: Lear Corporation WWTP
Inspection Date: 11/15/2024 Inspection Type: Compliance Evaluation
Bar Screens Yes No NA NE
Comment: Wastewater is gravity fed to the mechanical bar screen and accumulated material is
automatically placed into a container for proper disposal. The bar screen did not
appear to have a bypass line however, excessive debris is not normally found in this
waste stream.
Flow Measurement - Influent 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: Wastewater gravity flows through the bar screens and through a Parshall Flume with
electronic level sensor. Although the sensor is calibrated to calculate the flow into the
WWTP, this information is only used for internal purposes and is not reported on
eDMRs— nor is it required. However, the sensor was most recently calibrated
10/9/2024 by Clearwater, Inc.
Equalization Basins Yes No NA NE
Is the basin aerated? ❑ 0 ❑ ❑
Is the basin free of bypass lines or structures to the natural environment? 0 ❑ ❑ ❑
Is the basin free of excessive grease? ■ ❑ ❑ ❑
Are all pumps present? 0 ❑ ❑ ❑
Are all pumps operable? 0 ❑ ❑ ❑
Are float controls operable? ❑ ❑ 0 ❑
Are audible and visual alarms operable? ❑ ❑ 0 ❑
# Is basin size/volume adequate? ❑ ❑ ❑ ■
Comment: Wastewater gravity flows from the Parshall Flume into the 2 MG EQ basin. The basin is
constructed of concrete and has been equipped with a plastic liner. The basin has a
number system along the berm wall to monitor the level of wastewater. The level gin
the basin was at six feet during the inspection (i.e. at least 6 feet of freeboard).
Accumulated solids have recently been removed solids from the basin. The system
has obtained quotes for the re-installation of the two aerators and mixer and expect to
have these items re-installed in the near future. The basin has two pumps which have
submerged inlets in the basin and pump effluent to the aeration basin.
Aeration Basins Yes No NA NE
Mode of operation Ext. Air
Type of aeration system Surface
Is the basin free of dead spots? ❑ ■ ❑ ❑
Are surface aerators and mixers operational? 0 ❑ ❑ ❑
Page# 6

Docusign Envelope ID: EE9C06CF-D83D-4CCF-86CE-A3C23FOAD3DO
Permit: NC0002305 Owner-Facility: Lear Corporation WWTP
Inspection Date: 11/15/2024 Inspection Type: Compliance Evaluation
Aeration Basins Yes No NA NE
Are the diffusers operational? ❑ ❑ 0 ❑
Is the foam the proper color for the treatment process? ■ ❑ ❑ ❑
Does the foam cover less than 25% of the basin's surface? ❑ 0 ❑ ❑
Is the DO level acceptable? 0 ❑ ❑ ❑
Is the DO level acceptable?(1.0 to 3.0 mg/1) 0 ❑ ❑ ❑
Comment: Wastewater from the EQ basin is pumped into the 2 MG aeration basin with 11 floating
aerators. The aeration basin is also constructed of concrete. Only three of the
floating aerators were operational during the visit. The facility does not currently have
plans to operate another three aerators and the remaining aerators are in various
degrees of assessment or repairs. Noticeable dead spots were observed within the
basin. A polymer (63T) is added to the effluent of the aeration basin.
Secondary Clarifier Yes No NA NE
Is the clarifier free of black and odorous wastewater? 0 ❑ ❑ ❑
Is the site free of excessive buildup of solids in center well of circular clarifier? ■ ❑ ❑ ❑
Are weirs level? 0 ❑ ❑ ❑
Is the site free of weir blockage? 0 ❑ ❑ ❑
Is the site free of evidence of short-circuiting? ■ ❑ ❑ ❑
Is scum removal adequate? ■ ❑ ❑ ❑
Is the site free of excessive floating sludge? 0 ❑ ❑ ❑
Is the drive unit operational? 0 ❑ ❑ ❑
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) ❑ ❑ ❑
Comment: Wastewater gravity flows from the aeration basin into a splitter box and gravity flows to
one of two 55-feet diameter secondary clarifiers. The dissolved oxygen within the
splitter box is typically around 1 mg/L and MLSS can average between 8,000-9,000
mg/L, although the operator is making adjustments to attempt to lower this to between
4,000-5,000 mg/L. From the secondary clarifiers, wastewater gravity flows into a
60-feet diameter tertiary clarifier which mixes with alum for further clarification.
Although sludge levels may be high in the clarifiers (at -40% of wall height), it has
been reduced with sludge removal activities. Sludge removal will continue to be a
costly part of system operations.
Chemical Feed Yes No NA NE
Is containment adequate? ❑ 0 ❑ ❑
Is storage adequate? ■ ❑ ❑ ❑
Are backup pumps available? 0 ❑ ❑ ❑
Page# 7

Docusign Envelope ID: EE9C06CF-D83D-4CCF-86CE-A3C23FOAD3D0
Permit: NC0002305 Owner-Facility: Lear Corporation WWTP
Inspection Date: 11/15/2024 Inspection Type: Compliance Evaluation
Chemical Feed Yes No NA NE
Is the site free of excessive leaking? 0 ❑ ❑ ❑
Comment: The system is currently using a polymer (E63T)which is added to the effluent chamber
within the aeration basin, alum which is added to the tertiary clarifier and a defoaminq
agent which is infected into a final compartment of the chlorine contact tank. Nitrogen
was not being fed into the system during the recent inspection. It should be noted that
the -275 gallon plastic tote containing a defoaminq agent and numerous other waste
tanks containing smaller amounts of other compounds should be equipped with
secondary containment. A crack has been documented on the concrete 500,000
gallon sludge holding tank. The system has made plans to further investigate and
make repairs in the near future.
Pumps-RAS-WAS Yes No NA NE
Are pumps in place? 0 ❑ ❑ ❑
Are pumps operational? 0 ❑ ❑ ❑
Are there adequate spare parts and supplies on site? 0 ❑ ❑ ❑
Comment: WAS from the secondary clarifiers is pumped to the 1 MG aerobic digester and RAS
from the secondary clarifiers is pumped to the aeration basin. MLSS from the tertiar rL
clarifier goes to a gravity sludge thickener tank where filtrate goes back to the EQ
basin and sludge is pumped to the 1 MG aerobic digester.
Aerobic Digester Yes No NA NE
Is the capacity adequate? ❑ ❑ ❑ ■
Is the mixing adequate? ■ ❑ ❑ ❑
Is the site free of excessive foaming in the tank? ■ ❑ ❑ ❑
# Is the odor acceptable? 0 ❑ ❑ ❑
# Is tankage available for properly waste sludge? 0 ❑ ❑ ❑
Comment: Sludge from the tertiary clarifier is sent to the Sludge Thickener Tank. Filtrate from the
Sludge Thickener Tank goes to the Filtrate Tank and then to the EQ Basin. Sludge
from the Sludge Thickener Tank is sent to the aerobic digester tank where it is mixed
with sludge from the secondary clarifiers. Filtrate from the aerobic digester is sent to
the EQ basin and sludge is sent to the 500,000 gal sludge tank.
Drying Beds Yes No NA NE
Is there adequate drying bed space? 0 ❑ ❑ ❑
Is the sludge distribution on drying beds appropriate? ■ ❑ ❑ ❑
Are the drying beds free of vegetation? 0 ❑ ❑ ❑
# Is the site free of dry sludge remaining in beds? 0 ❑ ❑ ❑
Is the site free of stockpiled sludge? 0 ❑ ❑ ❑
Is the filtrate from sludge drying beds returned to the front of the plant? ■ ❑ ❑ ❑
Page# 8

Docusign Envelope ID: EE9C06CF-D83D-4CCF-86CE-A3C23FOAD3D0
Permit: NC0002305 Owner-Facility: Lear Corporation WWTP
Inspection Date: 11/15/2024 Inspection Type: Compliance Evaluation
Drying Beds Yes No NA NE
# Is the sludge disposed of through county landfill? 0 ❑ ❑ ❑
# Is the sludge land applied? ❑ ■ ❑ ❑
(Vacuum filters) Is polymer mixing adequate? 0 ❑ ❑ ❑
Comment: Although the system was previously equipped with 12 sand drying beds, system staff
have removed a few partition walls to reduce the number of beds to 8 and enabling the
easier access in the beds for heavy equipment to periodically clean out the structures.
The system periodically contracts with EMA, who separates the sludge with their mobile
belt press. All sludge is currently being taken to the Sampson County Landfill for
disposal.
Solids Handling Equipment Yes No NA NE
Is the equipment operational? 0 ❑ ❑ ❑
Is the chemical feed equipment operational? 0 ❑ ❑ ❑
Is storage adequate? ■ ❑ ❑ ❑
Is the site free of high level of solids in filtrate from filter presses or vacuum filters? ❑ ❑ 0 ❑
Is the site free of sludge buildup on belts and/or rollers of filter press? ❑ ❑ 0 ❑
Is the site free of excessive moisture in belt filter press sludge cake? ❑ ❑ 0 ❑
The facility has an approved sludge management plan? ❑ ❑ ❑
Comment: The rotating drum thickener on site was not in operation during the inspection.
Disinfection-Liquid Yes No NA NE
Is there adequate reserve supply of disinfectant? 0 ❑ ❑ ❑
(Sodium Hypochlorite) Is pump feed system operational? ■ ❑ ❑ ❑
Is bulk storage tank containment area adequate? (free of leaks/open drains) 0 ❑ ❑ ❑
Is the level of chlorine residual acceptable? ■ ❑ ❑ ❑
Is the contact chamber free of growth, or sludge buildup? 0 ❑ ❑ ❑
Is there chlorine residual prior to de-chlorination? 0 ❑ ❑ ❑
Comment: The chlorine contact chamber is a circular tank with baffle walls to slow the flow down to
allow enough contact time. The system staff have added additional baffles within the
tank to increase contact time. The site uses 15% sodium hypochlorite solution for
disinfection which is infected into the entry of the tank.
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 ❑ ❑ ❑
Page# 9

Docusign Envelope ID: EE9C06CF-D83D-4CCF-86CE-A3C23FOAD3D0
Permit: NC0002305 Owner-Facility: Lear Corporation WWTP
Inspection Date: 11/15/2024 Inspection Type: Compliance Evaluation
Flow Measurement - Effluent Yes No NA NE
(If units are separated) Does the chart recorder match the flow meter? ❑ ❑ 0 ❑
Comment: The system has a liquid level sensor which was calibrated 10/9/2024 by Clearwater,
Inc. The sensor data is combined with controls to estimate effluent flow rates which are
reported on DMRs.
De-chlorination Yes No NA NE
Type of system ? Liquid
Is the feed ratio proportional to chlorine amount (1 to 1)? ❑ ❑ ❑
Is storage appropriate for cylinders? 0 ❑ ❑ ❑
# Is de-chlorination substance stored away from chlorine containers? 0 ❑ ❑ ❑
Comment: 40% sodium biosulfate solution for de-chlorination solution is added as flow leaves the
chlorine contact tank.
Are the tablets the proper size and type? ❑ ❑ ❑
Are tablet de-chlorinators operational? ❑ ❑ ❑
Number of tubes in use?
Comment:
Effluent Sampling Yes No NA NE
Is composite sampling flow proportional? M ❑ ❑ ❑
Is sample collected below all treatment units? 0 ❑ ❑ ❑
Is proper volume collected? 0 ❑ ❑ ❑
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: The liquid in the effluent chamber of the chlorine contact tank appeared clear with no
evidence of floating solids or foam. The effluent sampler draws liquid from a manhole
installed along the effluent pipe south of the chlorine contact tank. The storage
chamber of the effluent composite sampler was at 3.6 degrees Celsius at the time of
inspection. It should be noted however that the length of the sample line travels within
a conduit and draws liquid from a downgradient manhole. The length of this tubing
should be visible to inspect for condition.
Effluent Pipe Yes No NA NE
Is right of way to the outfall properly maintained? 0 ❑ ❑ ❑
Are the receiving water free of foam other than trace amounts and other debris? 0 ❑ ❑ ❑
Page# 10

Docusign Envelope ID: EE9C06CF-D83D-4CCF-86CE-A3C23FOAD3DO
Permit: NC0002305 Owner-Facility: Lear Corporation WWTP
Inspection Date: 11/15/2024 Inspection Type: Compliance Evaluation
Effluent Pipe Yes No NA NE
If effluent (diffuser pipes are required) are they operating properly? ❑ ❑ 0 ❑
Comment: Outfall 001 is located approximately 3,600 feet east-southeast of the effluent pump
station in the Northeast Cape Fear River, Stream Index 18-74-(1), Sub-basin 03-06-22,
HUC030300070206, which has a classification of C;Sw, which is reserved for waters
protected for uses such as aquatic life propagation, wildlife and secondary recreation
of swamp waters. Although the effluent line is submerged in the reiver and could not
be discerned during the recent inspection, no noticeable foam or floating solids were
observed in the river. The cat walk along the lenqth of the discharge line leading to
the river had missing wood planks and handrails which need to be replaced.
Upstream / Downstream Sampling Yes No NA NE
Is the facility sampling performed as required by the permit (frequency, sampling type, ■ ❑ ❑ ❑
and sampling location)?
Comment: Up and downstream sampling was required with the prior 2018 permit and the current
draft permit. Upstream samples are required approximately one mile upstream and NE
of the site (Goshen Swamp at the NC Hwy 11 Bridge) and approximately one mile
downstream and SW of the site (Sarecta Road Bridge) in the NE Cape Fear River.
Historical averages from 5/6/2016 through 9/30/2024 for select parameters are
provided below:
Parameter Upstream Effluent Downstream
Dissolved Oxygen (mg/L) 5.08 7.23 5.81
Temperature (°C) 22.6 21.9 22.5
Conductivity (umhos/cm) 163.4 403.1 181.4
The system staff expressed concerns about safely obtaining upstream and
downstream samples. Although not discussed during the recent inspection (although
discussed during prior inspections), please be informed the system has the option to
join a voluntary program which will obtain these samples. The program is the Lower
Cape Fear River Monitoring Coalition and David Hill is the Coalition Coordinator and he
can be reached at 919-743-8431.
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