NC0056855_Regional Office Historical File Pre 2018

6
n 'NA 7 Michael F.Easley,Governor I
-,Q
�� �i William G.Ross Jr.,Secretary
Cq North Carolina Department of Environment and Natural Resources
> Alan W.Klimek,P.E.,Director
< Division of Water Quality
January 24, 2007
Mr. Mike Church, Environmental Engineer
Pharr Yarns, Inc.
Post Office Box 1939
McAdenville, North Carolina 28101-1939
Subject: Compliance Evaluation Inspection
Pharr Yarns Complex 46 WWTP
NPDES Permit No. NC0056855
Gaston County,North Carolina
Dear Mr. Church,
Enclosed please find a copy of the Compliance Evaluation Inspection Report for the
inspection conducted at the subject facility on January 22, 2007, by Mrs. Sonja Basinger of this
Office.
The report should be self-explanatory; however, should you have any questions
concerning the report, please do not hesitate to contact Mrs. Basinger or me at(704) 663-1699.
Sincerely,
•
for Michael L. Parker
Acting Surface Water Protection Regional Supervisor
Enclosure
cc: Gaston County Health Department
SWB
AIM
N.C.Division of Water Quality,Mooresville Regional Office,610 East Center Avenue,Suite 301,Mooresville NC 28115 [phone] Customer Service
1-877-623-6748

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 II NI 2 LI 3I NC0056855 1 11 121 07/01/22 117 181,IJ t 191 �IJ 1 20u
J I Remarks
21I I I I 1 1 1 1 IIII 1 1 1 1 I I I I I I I I 1 1 1 1 I I I I I I I I I I I I IIII I 1166
Inspection Work Days Facility Self-Monitoring Evaluation Rating B1 QA ------------------------Reserved
671 2.0 1 69 70I 3 I 71 U 721 n,I 73I I 174 75I 1 I I I I I 1 80
1 �u--� Section B: Facilit_ty.!Data lJ `
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)
02:53 PM 07/01/22 05/05/01
Complex 46 WWTP
200 Saxony Dr • Exit Time/Date Permit Expiration Date
Mc Adenville NC 28101 03:03 PM 07/01/22 10/01/31
Name(s)of Onsite Representative(s)/Titles(s)/Phone and Fax Number(s) Other Facility Data
///
Anderson Mike Church//704-823-2310 /
Name,Address of Responsible Official/Title/Phone and Fax Number
Contacted
Mike Church,PO Box 1939 Mc Adenville NC 28101//704-823-2310/7048241403
0
Section C: Areas Evaluated During Inspection(Check only those areas evaluated)
II Permit II Flow Measurement Operations&Maintenance •Records/Reports
I.Self-Monitoring Program •Sludge Handling Disposal El Facility Site Review •Effluent/Receiving Waters
1.Laboratory
Section D: Summary of Findinq/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
Sonja Basinger MRO WQ//704-235-2202/
I J r -/ 1- /
Signature of Management/�,� Q A Reviewer Agency/Office/Phone and Fax Numbers Date
011
Marcia cY6'Z�o� '''" - -- MRO WQ//704-235-2204/ i' 1 +
EPA Form 3560-3(Rev 9-94)Previous editions are obsolete.
Page# 1

Permit: NC0056855 Owner-Facility: Complex 46 VWVfP
Inspection Date: 01/22/2007 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? 0 0 • 0
Is the facility as described in the permit? ■ ❑ ❑ ❑
#Are there any special conditions for the permit? 0 0 ■ 0
Is access to the plant site restricted to the general public? ■ ❑ ❑ ❑
Is the inspector granted access to all areas for inspection? ■ ❑ ❑ ❑
Comment:
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? 0 0 ■ ❑
(If the facility is=or>5 MGD permitted flow)Do they operate 24/7 with a certified operator on each shift? 0 0 ■ 0
Is the ORC visitation log available and current? ■ ❑ ❑ ❑
Is the ORC certified at grade equal to or higher than the facility classification? 0 0 • 0
Is the backup operator certified at one grade less or greater than the facility classification? 0 0 • 0
Is a copy of the current NPDES permit available on site? ■ ❑ ❑ ❑
Facility has copy of previous year's Annual Report on file for review? 0 0 • 0
Comment: The facility was last inspected on September 29, 2005 by Wes Bell of this
Office.
DMRs were reviewed from November 2005 through October 2006. No limit violations
were reported.
Page# 3

Permit: NC0056855 Owner-Facility: Complex 46 W\NTP
Inspection Date: 01/22/2007 Inspection Type: Compliance Evaluation
Operations & Maintenance Yes No NA NE
Is the plant generally clean with acceptable housekeeping? ■ n ❑ ❑
Does the facility analyze process control parameters, for ex: MLSS, MCRT, Settleable Solids, pH, DO, Sludge ■ ❑ ❑ ❑
Judge, and other that are applicable?
Comment:
Laboratory Yes No NA NE
Are field parameters performed by certified personnel or laboratory'? ■ ❑ ❑ ❑
Are all other parameters(excluding field parameters)performed by a certified lab? ❑ ❑ ■ ❑
#Is the facility using a contract lab? n n U ❑
Is proper temperature set for sample storage(kept at 1.0 to 4.4 degrees Celsius)? noon
Incubator(Fecal Coliform)set to 44.5 degrees Celsius+/-0.2 degrees? noon
Incubator(BOD)set to 20.0 degrees Celsius+/- 1.0 degrees? ❑ ❑ • ❑
Comment: Grab samples are required by the facility's permit.
Field parameters are performed by Pharr Yarns Lab certification #5278.
Flow Measurement- Effluent Yes No NA NE
#Is flow meter used for reporting? ❑ ❑ • 0
Is flow meter calibrated annually? n ❑ • 0
Is the flow meter operational? 0 0 • 0
(If units are separated)Does the chart recorder match the flow meter? ❑ ❑ • ❑
Comment: Instantaneous effluent flows are measured by multiplying the known
volume discharged from the autoclaves (non-contact cooling water) by the number of
batch discharges.
Effluent Sampling Yes No NA NE
Is composite sampling flow proportional? 0 0 ■ ❑
Is sample collected below all treatment units? 0 0 ■ 0
Is proper volume collected? 0 0 • 0
Is the tubing clean? 0 0 • 0
Is proper temperature set for sample storage(kept at 1.0 to 4.4 degrees Celsius)? 0 0 ■ 0
Is the facility sampling performed as required by the permit(frequency, sampling type representative)? ■ ❑ ❑ n
Comment:
Effluent Pipe Yes No NA NE
Is right of way to the outfall properly maintained? ■ ❑ ❑ 0
Page# 4

Permit: NC0056855 Owner-Facility: Complex 46 WWTP
Inspection Date: 01/22/2007 Inspection Type: Compliance•Evaluation
Effluent Pipe Yes No NA NE
Are the receiving water free of foam other than trace amounts and other debris? ■ ❑ ❑ ❑
If effluent (diffuser pipes are required) are they operating properly? 0 0 • 0
Comment: There was foam present at dock#2 prior to discharge. The staff was
called to address the foam issue during the inspection.
Upstream/Downstream Sampling Yes No NA NE
Is the facility sampling performed as required by the permit(frequency, sampling type,and sampling location)? ■ 0 0 0
Comment:
Page# 5

a' W�QF A TFiQO Michael F.Easley,Governor O G
William G.Ross Jr.,Secretary
rNorth Carolina Department of Environment and Natural Resources
p Alan W.Klimek,P.E.Director
Division of Water Quality
December 15, 2006 pin
5278
Mr. Mike Church •
Pharr Yarns, Inc. DEC
PO Box 1939
McAdensville, NC 28101-
SUBJECT: Wastewater/Groundwater Laboratory Certification Renewal t : "
Field Parameters Only
Dear Mr. Church:
The Department of Environment and Natural Resources, in accordance with the
provisions of NC GS 143-215-.3 (a) (10), 15 NCAC 2H .0800, is pleased to renew
certification for your laboratory to perform specified environmental analyses required by
EMC monitoring and reporting regulations 15 NCAC 2B .0500, 2H .0900 and 2L .0100,
.0200, .0300, and 2N .0100 through .0800.
Enclosed for your use is a certificate describing the requirements and limits of your
certification. Please review this certificate to insure that your laboratory is certified for all
parameters required to properly meet your certification needs.
Please contact us at 919-733-3908 if you have questions or need additional
information.
•
Sincerely, •
Pat Donnelly
Branch Manager
Enclosure
cc: Chet Whiting
Mooresville Regional Office
NO;th Carol inn
Naturally
Laboratory Section 1623 Mail Service Center Raleigh,NC 27699-1623 Phone[phone] Customer Service
Internet: uww.duglab.or5 Location:4405 Reedy Creek Road Raleigh,NC 27607 Fax [phone]
An Equal Opportunity/Affirmative Action Employer-50%Recycled/I 0%Post Consumer Paper

STATE OF NORTH CAROLINA DEPARTMENT OF THE
ENVIRONMENT AND NATURAL RESOURCES
DIVISION OF WATER QUALITY
LABORATORY CERTIFICATION PROGRAM
In accordance with the provisions of N.C.G.S. 143-215.3(a)(1), 143-215.3(a)(10)and NCAC 2H.0800:
Field Parameter Only
7,,,4. STATE scirN,
M^0 n rnr /1/8.
1
. ssitrrr �
,,
K.........._
.. ,r > _.....,%.„. _. n%
-�t W i
-=-; ~ ..4?;1pRJL 12 17r‘'
.
`S'StQUAM\t4
PHARR YARNS, INC.
Is hereby certified to perform environmental analysis as listed on Attachment I and report monitoring data to DWQ for
compliance with NPDES effluent, surface water,groundwater,and pretreatment regulations.
By reference 15A NCAC 2H.0800 is made a part of this certificate.
This certificate does not guarantee validity of data generated,but indicates the methodology, equipment,quality control procedures,
records, and proficiency of the laboratory have been examined and found to be acceptable.
This certificate shall be valid until December 31,2007
Certificate No. 5278
1
7 6-‘. .2 '. •"-'0,r...-1.4:(. 2..,,-
Pat Donnelly
t

Attachment
North Carolina Wastewater/Groundwater Laboratory Certification
Certified Parameters Listing
FIELD PARAMETERS ONLY
ab Name: Pharr Yams, Inc. Certificate Number: 5278
,ddress: PO Box 1939 Effective Date: 01/01/2007
McAdensville,NC 28101- Expiration Date: 12/31/2007
Date of Last Amendment:
he above named laboratory,having duly met the requirements of 15A NCAC 2H.0800,is hereby certified for the measurement of the parameters listed below.
CERTIFIED PARAMETERS 1
NORGANICS
tESIDUAL CHLORINE
Std Method 4500 CI G
;ONDUCTIVITY
Std Method 2510E
)ISSOLVED OXYGEN
Std Method 4500 0 G
H
Std Method 4500 H B
tESIDUE SETTLEABLE
Std Method 2540F
'EMPERATURE
Std Method 2550E
its certification requires maintance of an acceptable quality assurance program,use of approved methodology,and satisfactory performance on evaluation samples. Laboratories are
bject to civil penalties and/or decertification for infractions as set forth in 15A NCAC 2H.0807.

OF VV A r - 64111—
rn
Michael F.Easley,Governor/1
,,,- �"'l�Q William G. Ross Jr.,Secretary
r \� G North Carolina Department of Environment and Natural Resources
yelja7 Alan W.Klimek,P.E. Director
� �* —I Division of Water Quality
1 '
October 5, 2005
Mr. Mike Church,Environmental Engineer
Pharr Yarns,Inc.
Post Office Box 1939
McAdenville,North Carolina 28101-1939
Subject: Compliance Evaluation Inspection
Pharr Yarns Complex 46
•
NPDES Permit No.NCOO56855
Gaston County,N.C.
Dear Mr. Church:
•
Enclosed is a copy of the Compliance Evaluation Inspection Report for the inspection
conducted at the subject facility on September 29,2005 by Mr. Wes Bell of this Office.
•
The report should be self-explanatory; however, should you have any questions concerning
this report,please do not hesitate to contact Mr.Bell or me at(704)663-1699.
Sincerely,
•
r i 1
,-, D. Rex Gleason, P.E.
Surface Water Protection Regional Supervisor
Enclosure
cc: Gaston County Health Department
WB
•
One
NotthCtu•ohna
Naturally
ititA iv,
NCDEN
N.C. Division of Water Quality,Mooresville Regional Office,610 E.Center Ave.Suite 301,Mooresville NC 28115 [phone] Customer Service
1-877-623-6748

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 LJ 1NI 2 IGI 31 NC0056855 111 121 05/09/29 17 181 �1 191G1 201
!J IRemarks LJ U U
21I 1 1 1 I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I 166
Inspection Work Days Facility Self-Monitoring Evaluation Rating B1 QA - — —Reserved
671 1.5 169 70 14 I 711 i 7I 72 I NI 731 I 174 751 I I I I I I 180
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)
01:38 PM 05/09/29 05/05/01
Complex 46 WWTP -
200 Saxony Dr Exit Time/Date Permit Expiration Date
McAdenville NC 28101 01:46 PM 05/09/29 10/01/31
Name(s)of Onsite Representative(s)/Titles(s)/Phone and Fax Number(s) Other Facility Data
///
Anderson Mike Church/ORC/704-823-2310/
James Lester Davis//704-824-3551 /
Name,Address of Responsible Official/Title/Phone and Fax Number
Contacted
Mike Church,PO Box 1939 McAdenville NC 28101//704-823-2310/7048241403
Yes
Section C: Areas Evaluated During Inspection(Check only those areas evaluated)
II Permit Flow Measurement II Operations&Maintenance 111 Records/Reports
II Self-Monitoring Program II Facility Site Review II Effluent/Receiving Waters II 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
Wesley N Bell /` /�/? MRO WQ//704-663-1699 Ext.231/ /© /5/0_ .
Signature of Management Q A Reviewer Agency/Office/Phone and Fax Numbers Date
Richard M Bridgeman 704-663-1699 Ext.264/
EPA Form 3560-3(Rev 9-94)Previous editions are obsolete.

Permit: NC0056855 Owner-Facility: Complex 46 WWTP
Inspection Date: 09/29/2005 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? 0 0 • 0
Is the facility as described in the permit? U ❑ ❑ ❑
Are there any special conditions for the permit? 0 0 • 0
Is access to the plant site restricted to the general public? ■ ❑ ❑ ❑
Is the inspector granted access to all areas for inspection? • ❑ ❑ ❑
Comment:
Operations&Maintenance Yes No NA NE
Is the plant generally clean with acceptable housekeeping? U ❑ ❑ ❑
Does the facility analyze process control parameters,for ex:MLSS,MCRT,Settleable Solids,pH,DO,Sludge 0 0 • 0
Judge,and other that are applicable?
Comment:
Laboratory Yes No NA NE
Are field parameters performed by certified personnel or laboratory? ■ ❑ ❑ ❑
Are all other parameters(excluding field parameters)performed by a certified lab? • 0 0 0
Is the facility using a contract lab? ■ ❑ n n
Is proper temperature set for sample storage(kept at 1.0 to 4.4 degrees Celsius)? • ❑ ❑ ■ ❑
Incubator(Fecal Coliform)set to 44.5 degrees Celsius+/-0.2 degrees? 0 0 • 0
Incubator(BOD)set to 20.0 degrees Celsius+/-1.0 degrees? 0 0 • 0
Comment:On-site field analyses are performed under laboratory certification#5278.
Flow Measurement-Effluent Yes No NA NE
Is flow meter used for reporting? 0 0 • 0
Is flow meter calibrated annually? nnsin
Is the flow meter operational? 0 0 • 0
(If units are separated)Does the chart recorder match the flow meter? 0 0 ■ 0
Comment:Instantaneous effluent flows are measured by multiplying the known volume discharged from the
autoclaves by the number of batch discharges.
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? U ❑ ❑ ❑
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? 0 0 • 0
(If the facility is=or>5 MGD permitted flow)Do they operate 24/7 with a certified operator on each shift? ❑ ❑ U
Is the ORC visitation log available and current? U ❑ ❑ ❑

Permit: NC0056855 Owner-Facility: Complex 46 WWTP
Inspection Date: 09/29/2005 Inspection Type: Compliance Evaluation
Record Keeping Yes No NA NE
Is the ORC certified at grade equal to or higher than the facility classification? 0 0 • 0
Is the backup operator certified at one grade less or greater than the facility classification? 0 0 • 0
Is a copy of the current NPDES permit available on site? U ❑ ❑ ❑
Facility has copy of previous year's Annual Report on file for review? 0 0 • 0
Comment:DMRs were reviewed from July 04 through June 05. No limit violations were reported. The facility staff
incorporate a commendable record keeping program.
Effluent Sampling Yes No NA NE
Is composite sampling flow proportional? ❑ ❑ • ❑
Is sample collected below all treatment units? 0 ❑ • ❑
Is proper volume collected? _ ❑ ❑ ■ ❑
Is the tubing clean? 0 ❑ • 0
Is proper temperature set for sample storage(kept at 1.0 to 4.4 degrees Celsius)? 0 0 • 0
Is the facility sampling performed as required by the permit(frequency,sampling type representative)? U ❑ ❑ ❑
Comment:The permit only requires flow and temperature measurements.
Upstream/Downstream Sampling Yes No NA NE
Is the facility sampling performed as required by the permit(frequency,sampling type,and sampling location)? U ❑ ❑ ❑
Comment:
Effluent Pipe • Yes No NA NE
Is right of way to the outfall properly maintained? ❑ 0 0 •
Are the receiving water free of foam other than trace amounts and other debris? U ❑ ❑ ❑
If effluent (diffuser pipes are required) are they operating properly? 0 0 • 0
Comment:The effluent appeared clear with no suspended solids or foam.

Ea 1'or 0) W A 7- 9 Michael F. y,Governor
0 0 William G.Ross Jr„Secretary
7 North Carolina Department of Environment and Natural Resources
> - Alan W.Klimek,P.E.Director
O 'C Division of Water Quality
September 14, 2004
Mr. Mike Church
Pharr Yarns, Inc.
P.O. Box 1939
McAdenville,North Carolina 28101
Subject: Compliance Evaluation Inspection
Pharr Yarns Industrial WWTP
NPDES Permit No.NC0004812
Pharr Yarns Complex 46
NPDES Permit No. NC0056855
Gaston County,NC
Dear Mr. Church:
Enclosed are copies of the Compliance Evaluation Inspection Reports for the
inspections conducted at the subject facilities on September 9, 2004 by Mr. Barry Love of
this Office.
The reports should be self-explanatory; however, should you have any questions
concerning these reports, please do not hesitate to contact Mr. Love or me at (704) 663-
1699.
Sincerely,
\1 D. Rex Gleason, P.E.
Surface Water Protection Regional Supervisor
Enclosure
cc: Gaston County Health Department
BL oN, atCrrao!y A_A
r b
N.C. Division of Water Quality, Mooresville Regional Office, 919 North Main Street, Mooresville NC 28115 [phone] Customer Service
1-877-623-6748

United States Environmental Protection Agency
EPA Washtrpton,D.C.20460 Form No OMB No..2040-040-
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 lNl 2 U 3I NC0004812 111 121 04/09/09 117 16iCi 19LSi 20I
LLJJ lJ Remarks 1LJJ LUJ LJ
211 I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I 166
Inspection Work Days Facility Self-Monitoring Evaluation Rating B1 QA Reserved
67 I 3.0 169 70 lJ 71 1 J 72 IA 73 11 174 751 1 1 I 1 1 1 1 60
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)
09:45 AM 04/09/09 02/07/01
Pharr Yarns Industrial WWTP
147 Willow Dr Exit Time/Date Permit Expiration Date
McAdenville NC 26101 11:15 AM 04/09/09 05/01/31
Name(s)of Onsite Representative(s)/Titles(s)/Phone and Fax Number(s) Other Facility Data
Anderson Mike Church/ORC/704-823-2310/
///
Name,Address of Responsible OfficiallTiitle/Phone and Fax Number
Co�tcted
Mike Church,PO Box 1939 McAdenville NC 28101!/7046293551310/7048241
Section C: Areas Evaluated During Inspection(Check only those areas evaluated)
Permit is Flow Measurement •Operations&Maintenance I.Records/Reports
1111 Self-Monitoring Program II Sludge Handling Disposal •Facility Site Review III Effluent/Receiving Waters
II Laboratory
Section D: Summary of Finding/Comments(Attach additional sheets of narrative and checklists as necessary)
(See attachment summary)
Na(s)and Signat (s) Inspector(s) Agency/Office/Phone and Fax Numbers Date
et..-c---/� -t/r Li-/.9 4-
Barry F Love MRO WQ//704-663-1699/704-663-6040
Signature of Management Q A Reviewer Agency/Office/Phone and Fax Numbers Date
Richard M Bridgeman 704-6E3-1699/704-663-6040
EPA Form 3560-3(Rev 9-94)Previous editions are obsolete.

Permit: NC0004812 Owner-Facility: Pharr Yams Inc-Pharr Yams Industrial WWTP
Inspection Date: 09/09/04 inspection Type: Compliance Evaluation
Permit Ywc No NA NF
(If the present permit expires in 6 months or less). Has the permitlee submitted a new application? • ❑ ❑ ❑
Is the facility as described in the permit? • 0 0 ❑
Are there any special conditions for the permit? ❑ N ❑ ❑
Is access to the plant site restricted to the general public? . 000
Is the inspector granted access to all areas for inspection? • ❑ ❑ ❑
Comment:
Onerations&Maintenanr.e YAS No NA NF
Does the plant have general safety structures in place such as rails around or covers over tanks,pits,or wells? N 0 ❑ 0
Is the plant generally clean with acceptable housekeeping? MOOD
Comment:
Sernndary Clarifier Yes No NA NF
Is the clarifier free of black and odorous wastewater? 1. 000
Is the site free of excessive buildup of solids in center well of circular clarifier? 0 • 0 0
Are weirs level? ❑ ❑ ❑
Is the site free of weir blockage? • ❑ ❑ ❑
Is the site free of evidence of short-circuiting? N ❑ ❑ ❑
Is scum removal adequate? • ❑ ❑ ❑
Is the site free of excessive floating sludge? ❑ ❑ ❑
Is the drive unit operational? N ❑ ❑ ❑
Is the sludge blanket level acceptable? 0001.
Is the return rate acceptable(low turbulence)? U ❑ ❑ 0
Is the overflow clear of excessive solids/pin floc? . 000
Is the surface free of bulking? 11000
Comment:Build up of solids was present in center well.
Aeration Basins Yes No NA NF
Mode of operation Ext.Air
Type of aeration system Surface
Is the basin free of dead spots? . 000
Are surface aerators and mixers operational? • ❑ ❑ ❑
Are the diffusers operational? 0 ❑ • 0
Is the foam the proper color for the treatment process? • ❑ ❑ ❑
Does the foam cover less than 25%of the basin's surface? ❑ E ❑ ❑
Is the DO level acceptable? • 000 .
Are settleometer results acceptable? ❑ 0 0 •
Comment:No problems were observed.
Filtration(High Rate Tertiary.) Yes Nn NA NF
Type of operation: Down flow
Is the filter media present? 000 .
Is the filter surface free of clogging? 0 0 ❑ �
Is the filter free of growth? ❑ ❑ ❑ M
Is the air scour operational? 0 0 • 0
Is the scouring acceptable? 0 0 • 0

Permit: NC0004812 Owner-Facility: Pharr Yams Inc-Pharr Yams Industrial WWTP
Inspection Date: 09/09/04 Inspection Type: Compliance Evaluation
Filtration(High Rate Tertiary) Yes No NA NF
Is the clear well free of excessive solids and filter media? DOOM
Does backwashing frequency appear adequate? . 000
Comment:
Disinfection Yes No NA NF
Type of system? Liquid
Are cylinders secured adequately? ❑ 0 • 0
Are cylinders protected from direct sunlight? 0 0 U ❑
Is there adequate reserve supply of disinfectant? MOOD
Is ventilation equipment operational? 0 0 MI 0
Is ventilation equipment properly located? ❑ 0 • 0
Is SCBA equipment available on site? ❑ ❑ • ❑
Is SCBA equipment operational? ❑ ❑ • 0
Is staff trained is operating SCBA equipment? ❑ ❑ • 0
Is staff trained in emergency procedures? ❑ 0 • ❑
Is an evacuation plan in place? ❑ 0 • 0
Are tablet chlorinators operational? ❑ ❑ • ❑
Are the tablets the proper size and type? U ❑ ❑ ❑
Number of tubes in use?
(Sodium Hypochlorite)Is pump feed system operational? • 0 0 0
Is bulk storage tank containment area adequate?(free of leaks/open drains) • ❑ ❑ 0
Is the level of chlorine residual acceptable? III 0 0 0
Is there adequate detention time • 0 0 0
Is the contact chamber free of growth,or sludge buildup? • ❑ 0 ❑
Comment:Aqueous calcium hypochlorite is injected into the waste stream either before the filters or in the contact
chamber or both.
J aboratory Yes Nn NA NF
Are field parameters performed by certified personnel or laboratory? • ❑ ❑ ❑
Are all other parameters(excluding field parameters)performed by a certified lab? ■ ❑ ❑ ❑
Is the facility using a contract lab? • ❑ ❑ ❑
Are analytical results consistent with data reported on DMRs? • ❑ ❑ 0
Is proper temperature set for sample storage(kept at 1.0 to 4.4 degrees Celsius)? U ❑ ❑ ❑
Incubator(Fecal Coliform)set to 44.5 degrees Celsius+/-0.2 degrees? 0 0 U 0
Incubator(BOD)set to 20.0 degrees Celsius+/-1.0 degrees? 00 . 13
Comment:Please see the lab inspection report by Chet Whiting.
Flow Measurement-Effluent Yes No NA NF
Is flow meter used for reporting? ROOD
Is flow meter calibrated annually? • ❑ ❑ ❑
Is flow meter operating properly? MOOD
(If units are separated)Does the chart recorder match the flow meter? • ❑ ❑ ❑
Comment:The flow meter was last calibrated on May 26,2004 by C.Wright Instruments. •
Record Keeping Yes No NA NF
Are records kept and maintained as required by the permit? 111000
Is all required information readily available,complete and current? I ❑ ❑ ❑

Permit: NC0004812 Owner-Facility: Pharr Yams Inc-Pharr Yams Industrial WWTP
inspection Date: 09/09/04 Inspection Type: Compliance Evaluation
Record Keening Yes Nn NA NF
Are all records maintained for 3 years(lab.reg.required 5 years)? U ❑ ❑ ❑
Are analytical results consistent with data reported on DMRs? • 0 0 ❑
• Are sampling and analysis data adequate and include: • 0 ❑ 0
Dates,times and location of sampling •
Name of individual performing the sampling U
Results of analysis and calibration U
Dates of analysis U
Name of person performing analyses U
Transported COCs •
Plant records are adequate,available and include U ❑ ❑ ❑
O&M Manual ❑
As built Engineering drawings ❑
Schedules and dates of equipment maintenance and repairs •
Are DMRs complete:do they include all permit parameters? • 0 0 0
Has the facility submitted its annual compliance report to users? 0 0 • 0
(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? • 0 0 ❑
Is the ORC certified at grade equal to or higher than the facility classification? U ❑ ❑ ❑
Is the backup operator certified at one grade less or greater than the facility classification? U ❑ ❑ ❑
Is a copy of the current NPDES permit available on site? • 0 0 0
Is the facility description verified as contained in the NPDES permit? U ❑ ❑ ❑
Does the facility analyze process control parameters,for example:MLSS,MCRT,Settleable Solids,DO,Sludge ❑ ❑ ❑
Judge,pH,and others that are applicable?
Facility has copy of previous year's Annual Report on file for review? 00110
Comment:DMR's were reviewed for the period of July 2003 through June 2004. Daily maximum limit violations for
BOD were reported on February 11,March 17,and April 14,2004. Monthly average limit violations for BOD were also
reported for March and April 2004. These violations have been addressed through previous correspondence.
Fff llPnt Sampling Yes No NA NF
Is composite sampling flow proportional? • 0 0 0
Is sample collected below all treatment units? • ❑ 0 ❑
Is proper volume collected? U ❑ ❑ ❑
Is the tubing clean? • ❑ 0 0
Is proper temperature set for sample storage(kept at 1.0 to 4.4 degrees Celsius)? • 0 0 0
Is the facility sampling performed as required by the permit(frequency,sampling type representative)? • ❑ ❑ ❑
Comment:
Upstream/Downstream Sampling Yes Nn NA NF
Is the facility sampling performed as required by the permit(frequency,sampling type,and sampling location)? U 0 0 ❑
Comment:
Aerobic Digester Yes No NA NF
Is the capacity adequate? U ❑ ❑ ❑
Is the mixing adequate? • ❑ 0 0
•
Is the site free of excessive foaming in the tank? ❑ 0 ❑
Is the odor acceptable? MOOD
Comment:

Permit: NC0004812 Owner-Facility: Pharr Yarns Inc-Pharr Yams Industrial WWTP
Inspection Date: 09/09/04 Inspection Type: Compliance Evaluation
,Snlidh Handling Fgttjpment Yes No NA NF
Is the equipment operational? 0 • 0 0
Is the chemical feed equipment operational? 0 0 0 •
Is storage adequate? IN 0 0 0
Is the site free of high level of solids in filtrate from filter presses or vacuum fillers? U ❑ ❑ ❑
Is the site free of sludge buildup on belts and/or rollers of filler press? U ❑ ❑ ❑
Is the site free of excessive moisture in belt filter press sludge cake? • ❑ ❑ ❑
Comment:The sludge press is currently not operational;nor does the facility does have a operator for this equipment.
Sludge is currently being stored in the digesters.
Chemical Feed Yes No NA NF
Is containment adequate? U ❑ ❑ ❑
Is storage adequate? • ❑ 0 0
Are backup pumps available? 00011
Is the site free of excessive leaking? • 0 0 0
Comment:
Fffli tent Pine Yes No NA NF
Is right of way to the outfall properly maintained? II 0 0 0
Are receiving water free of solids and floatable wastewater materials? • 0 0 ❑
Are the receiving waters free of solids/debris? • 0 ❑ 0
Are the receiving waters free of foam other than a trace? U ❑ ❑ ❑
Are the receiving waters free of sludge worms? 0 0 0 •
If effluent (diffuser pipes are required) are they operating properly? 0 0 • 0
Comment:Due to high river levels the receiving waters could not be accurately inspected.

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 Li 2 U 3I NC0056655 111 121 04/09/09 I 17 18[ J 19Lsj 2011
LLJJ Li
Remarks tu_1 uu
21IIII I I I I I11111I11111IIII I11111111111IIII I I I I I1166
Inspection Work Days Facility Self-Monitoring Evaluation Rating B1 QA Reserved
67I 2.0 I69 70IJ 71I2j 72IJ 731 I I74 751 1 1 1 I 1 1 I80
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)
12:35 PM 04/09/09 01/10,`01
Complex 46 WWTP
200 Saxony Dr Exit Time/Date Permit Expiration Date
McAdenvil]e NC 25101 12:40 PM 04 '09'09 05.01 ,1
Name(s)of Onsite Representative(s)/Titles(s)/Phone and Fax Number(s) Other Facility Data
Anderson Mike Church/ORC'704-623-2310/
///
Name,Address of Responsible Official/Title/Phone and Fax Number
Mike Church,PO Box 1939 McAdenville NC 26101r/704-62_-23:0/704624COfltacted
Section C: Areas Evaluated During Inspection(Check only0 those areas evaluated)
▪Permit III Flow Measurement II Operations&Maintenance II Records/Reports
▪Self-Monitoring Program MI Facility Site Review III Laboratory
Section D: Summary of Finding/Comments(Attach additional sheets of narrative and checklists as necessary)
(See attachment summary)
Nam and Signature(s)of Inspector(s) Agency/Office/Phone and Fax Numbers Date
s) - 9/r 4-t-/o it.
Barry F Love MRO WQ//704-663-1699/704-663-6040
Signature of Management Q A Reviewer Agency/Office/Phone and Fax Numbers Date
Richard M Bridgeman 704-663-1699/704-6E3-6040
EPA Form 3560-3(Rev 9-94)Previous editions are obsolete.

Permit: NC0056855 Owner-Facility: Pharr Yarns Inc-Complex 46 WWTP
Inspection Date: 09/09/04 Inspection Type: Compliance Evaluation
Permit Yes No NA NF
(If the present permit expires in 6 months or less). Has the permittee submitted a new application? ❑ • 0 0
Is the facility as described in the permit? U ❑ ❑ ❑
Are there any special conditions for the permit? 0 • ❑ ❑
Is access to the plant site restricted to the general public? 11000
Is the inspector granted access to all areas for inspection? • ❑ ❑ ❑
Comment:The permittee intends to install a line in the near future which will carry the condensate wastewater from the
autoclaves and air washer to the sanitary sewer system:thereby eliminating the need for the permit.
Operations&Maintenance Yes NO NA NF
Does the plant have general safety structures in place such as rails around or covers over tanks,pits,or wells? ❑ ❑ E ❑
Is the plant generally clean with acceptable housekeeping? M ❑ ❑ ❑
Comment:
j ahoratory Yes No NA NF
Are field parameters performed by certified personnel or laboratory? 1111000
Are all other parameters(excluding field parameters)performed by a certified lab? 0 ❑ • 0
Is the facility using a contract lab? ❑ ❑ E ❑
Are analytical results consistent with data reported on DMRs? • 000
Is proper temperature set for sample storage(kept at 1.0 to 4.4 degrees Celsius)? 0 ❑ 0 •
Incubator(Fecal Coliform)set to 44.5 degrees Celsius+/-0.2 degrees? ❑ 0 • 0
Incubator(BOD)set to 20.0 degrees Celsius+/-1.0 degrees? ❑ ❑ I ❑
Comment:Please review the report by Chet Whiting for more details.
Record Keeping Yes Nn NA NF
Are records kept and maintained as required by the permit? I ❑ ❑ ❑
Is all required information readily available,complete and current? I ❑ ❑ ❑
Are all records maintained for 3 years(lab.reg.required 5 years)? I ❑ ❑ ❑
Are analytical results consistent with data reported on DMRs? ❑ ❑ I ❑
Are sampling and analysis data adequate and include: 0 ❑ • 0
Dates,times and location of sampling 0
Name of individual performing the sampling ❑
Results of analysis and calibration ❑
Dates of analysis ❑
Name of person performing analyses 0
Transported COCs 0
Plant records are adequate,available and include I. 000
O&M Manual ❑
As built Engineering drawings 0
Schedules and dates of equipment maintenance and repairs ❑
Are DMRs complete:do they include all permit parameters? I ❑ ❑ ❑
Has the facility submitted its annual compliance report to users? ❑ ❑ I ❑
(If the facility is=or>5 MGD permitted flow)Do they operate 24/7 with a certified operator on each shift? 0 0 • ❑
Is the ORC visitation log available and current? U ❑ 0 0
Is the ORC certified at grade equal to or higher than the facility classification? M ❑ ❑ ❑
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? 11000

Permit: NC0056855 Owner-Facility: Pharr Yarns Inc-Complex 46 VWVTP
inspection Date: 09/09/04 Inspection Type: Compliance Evaluation
Record Keening Yes Nn NA NF
Is the facility description verified as contained in the NPDES permit? U 0E10
Does the facility analyze process control parameters,for example:MLSS,MCRT,Settleable Solids,DO,Sludge 001110
Judge,pH,and others that are applicable?
Facility has copy of previous year's Annual Report on file for review? � CI •
Comment:DMR's were reviewed for the period of July 2003 through June 2004. No flow was reported for the entire
review period.
Fffliient Sampling Yes No NA NF
Is composite sampling flow proportional? 11
0
Is sample collected below all treatment units? U
000
Is proper volume collected? MOOD
Is the tubing clean? 11
0
Is proper temperature set for sample storage(kept at 1.0 to 4.4 degrees Celsius)? E
Is the facility sampling performed as required by the permit(frequency,sampling type representative)? U
000
Comment:No discharge was reported for the review period,so no samples were collected.

Michael F. Easley
oc. wArFR .� Governor
0 NCDENR William G. Ross,Jr., Secretary
r North Carolina Department of Environment and Natural Resources
"c" Alan W. Klimek, P.E., Director
Division of Water Quality
May 13,2004
Mike Church
Pharr Yarns,Inc.
Pharr Yarns
McAdenville,NC 28101
Subject: Renewal Notice
NPDES Permit NC0056855
Complex 46 WWTP
Gaston County
Dear Permittee:
Your NPDES permit expires on January 31,2005. Federal(40 CFR 122.41)and North Carolina(15A NCAC
2H.0105(e)) regulations require that permit renewal applications must be filed at least 180 days prior to expiration of the current
permit. If you have already mailed your renewal application,you may disregard this notice.
To satisfy this requirement,your renewal package must be sent to the Division postmarked no later than August 4,
2004. Failure to request renewal by this date may result in a civil assessment of at least$500.00. Larger penalties may be assessed
depending upon the delinquency of the request.
If any wastewater discharge will occur after January 31,2005,the current permit must be renewed. Discharge of
wastewater without a valid permit would violate North Carolina General Statute 143-215.1;unpermitted discharges of wastewater
may be assessed civil penalties of up to$25,000 per day.
If all wastewater discharge has ceased at your facility and you wish to rescind this permit,contact Bob Sledge of the
Division's Compliance Enforcement Unit at(919) 733-5083,extension 547. You may also contact the Mooresville Regional
Office at(704)663-1699 to begin the rescission process.
Use the enclosed checklist to complete your renewal package. The checklist identifies the items you must submit with
the permit renewal application. If you have any questions,please contact me at the telephone number or e-mail address listed
below.
Sincerely,
1/(AN' )7-
NC DEPT.OF ENVIRONMENT
Charles H.Weaver,Jr. AND NATURAL RESOURCES
NPDES Unit MOORESw ' .,'-TONAL OFFir
7
ZAti
cc: Central Files
NPDES File MAY 2 0 2004
1617 Mail Service Center,Raleigh,North Carolina 27699-1617 919 733-5083,extension 511 (fax 71St lre". E `.,.
VISIT US ON THE INTERNET @ http://h2o.enr.state.nc.us/NPDES e-mail:[e-mail]

NPDES Permit NC0056855
Complex 46 WWTP
Gaston County
The following items are REQUIRED for all renewal packages:
❑ A cover letter requesting renewal of the permit and documenting any changes at the facility since
issuance of the last permit. Submit one signed original and two copies.
❑ The completed application form (copy attached), signed by the permittee or an Authorized
Representative. Submit one signed original and two copies.
❑ If an Authorized Representative (such as a consulting engineer or environmental consultant) prepares
the renewal package, written documentation must be provided showing the authority delegated to any
such Authorized Representative (see Part II.B.11.b of the existing NPDES permit).
❑ A narrative description of the sludge management plan for the facility. Describe how sludge (or other
solids) generated during wastewater treatment are handled and disposed. If your facility has no such
plan (or the permitted facility does not generate any solids), explain this in writing. Submit one signed
original and two copies.
The following items must be submitted by any Municipal or Industrial facilities discharging
process wastewater:
Industrial facilities classified as Primary Industries (see Appendices A-D to Tide 40 of the Code of Federal
Regulations, Part 122) and ALL Municipal facilities with a permitted flow >_ 1.0 MGD must submit a
Priority Pollutant Analysis (PPA) in accordance with 40 CFR Part 122.21.
The above requirement does NOT apply to privately owned facilities treating 100%
domestic wastewater, or facilities which discharge non process wastewater (cooling
water, filter backwash, etc.)
PLEASE NOTE:
Due to a change in fees effective January 1, 1999, there is no renewal fee required with your
application package.
Send the completed renewal package to:
Charles H. Weaver
NC DENR / Water Quality / NPDES Unit
1617 Mail Service Center
Raleigh, NC 27699-1617

1141(
Oh QGo W ATFR Michael F.E y,Governor J
William G.Ross,Jr.,Secretary
North Carolina Department of Environment and Natural Resources
Alan W.Klimek,P.E.,Director
p -C. Division of Water Quality
Coleen Sullins,Deputy Director
Division of Water Quality
August 8, 2003
Mr. Mile Church
Pharr Yarns, Inc.
P.O. Box 1939
McAdenville,NC 28101-1939
Subject: Compliance Evaluation Inspection
Pharr Yarns Complex 46
NPDES Permit No. NC0056855
Gaston County,NC
Dear Mr. Church:
Enclosed is a copy of the Compliance Evaluation Inspection Report for the inspection
conducted at the subject facility on August 5, 2003 by Mr. Barry Love of this Office.
The report should be self-explanatory; however, should you have any questions
concerning this report,please do not hesitate to contact Mr. Love or me at(704) 663-1699.
Sincerely,
R} 51. licu c--, -
D. Rex Gleason, P.E.
Water Quality Regional Supervisor
Enclosure
cc: Gaston County Health Department
BL
ona
NCDENR
Customer Service Mooresville Regional Office,919 North Main Street,Mooresville,NC 28115 PHONE [phone]
1 877-623-6748 FAX [phone]

United States Environmental Protection Agency
Washington,D.C.2otec Form Approved.
EPA 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 I„I 2 I I 3I NC0056855 ( 11 12 1 03/08/os 117 18 'c] 19I�,' 20
IA lJ Remarks 1 U u
211II1I1II1IIIIIIII11111IIIII11IIIIIIIIIIIIIIIII166
Inspection Work Days Facility Setf-Monitoring Evaluation Rating B1 QA Reserved
671
1.0 1 69 70 t t 71 I„l 72 I„t 731 I 174 751 1 1 1 1 1 1 180
t LJ Section B: Facility Data L J
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)
12:50 PM 03/08/05 01/10/01
Complex 46 WWTP
200 Saxony Drive Exit Time/Date Permit Expiration Date
McAdenville NC 28101 01:00 PM 03/08/05 05/01/31
Name(s)of Onsite Representative(s)/Tutles(s)/Phone and Fax Number(s) Other Facility Data
Anderson Mike Church/ORC/704-739-7200/
James Davis//704-824-3551/
Name,Address of Responsible Official/Title/Phone and Fax Number
Contacted
Mike Church,PO Box 1939 McAdenville NC 28101//704-823-2310/
No
Section C: Areas Evaluated During Inspection(Check only those areas evaluated)
Permit Flow Measurement Operations & Maintenance Records/Reports
Self-Monitoring Program Facility Site Review Effluent/Receiving Waters
Section D: Summary of Finding/Comments(Attach additional sheets of narrative and checklists as necessary)
Name s)and Signature s)of Inspector(s) Agency/Office/Phone and Fax Numbers Date
Barry F Love MRO WQ//704-663-1699/704-663-6040
Signature of Management Q A Reviewer Agency/Office/Phone and Fax Numbers Date
Richard M Bridgeman 704-663-1699/704-663-6040
EPA Form 3560-3(Rev 9-94)Previous editions are obsolete.

PERMIT:
The permit adequately describes the WWTP.
RECORDS AND REPORTS:
Records and reports consisting of discharge monitoring reports(DMR's),calibration logs and
Operator-in-Responsible Charge(ORC)/daily operation log were reviewed at the time of the inspection.
The records were organized and well maintained.
FACILITY SITE REVIEW/OPERATIONS&MAINTENANCE:
The surrounding grounds were well maintained. The facility is staffed with one Grade IV ORC.
A certified back-up operator has been designated and is available when the ORC is unable to visit the
facility. The operator was very knowledgeable of the treatment processes and equipment used at the
facility.
LABORATORY:
The staff at the Pharr Yarns WWTP laboratory(Certification#5278)in McAdenville,N.C.
perform the required analysis. The laboratory was not evaluated at the time of the inspection.
EFFLUENT/RECEIVING WATERS:
The facility was not discharging at the time of the inspection. The receiving stream was not
evaluated.
•
SELF-MONITORING PROGRAM:
Self-monitoring reports were reviewed for the period August 2002 through May 2003. The
facility did not report a discharge for the entire review period.
FLOW MEASUREMENT:
Instantaneous flow is measured by multiplying the known volume per autoclave(330
gallon/autoclave)by the number of discharges that occur.

FWATF f.
V
� 9QG Mich-�F.Easley /
Govemor �/
William G.Ross,Jr.,Secretary
> North Carolina Department of Environment and Natural Resources
5 T Alan W.Klimek,Director
Division of Water Quality
November 5, 2002
Mr. Mike Church, Environmental Engineer
Pharr Yams, Inc.
Post Office Box 1939
McAdenville,North Carolina 28101-1939
Subject: Compliance Evaluation Inspection
Pharr Yarns Complex 46
NPDES Permit No.NC0056855
Gaston County,N.C.
Dear Mr. Church:
Enclosed is a copy of the Compliance Evaluation Inspection Report for the inspection
conducted at the subject facility on October 30, 2002 by Mr. Wes Bell of this Office.
The report should be self-explanatory; however, should you have any questions concerning
this report, please do not hesitate to contact Mr. Bell or me at(704) 663-1699.
Sincerely,
R ..(14>,-,C (11 . gi4',,,,-,„(,..„
Rex Gleason, P.E.
Water Quality Regional Supervisor
Enclosure
cc: Gaston County Health Department
WB
1►7Q .
KMENR
Customer Service Mooresville Regional Office,919 North Main Street,Mooresville,NC 28115 PHONE [phone]
1 800 623-7748 FAX [phone]

w,k. US Environmental Protection Agency, Washington,D.C.,20460 Forrn Approved.
r�A!�'�� Water Compliance Inspection Report
�i OMB No 2040-0057
�'�a NC Division of Water Quality/Mooresville Regional Office NCDENR Approval Expires 5-31-98
Sectioned WationalDataSystem•Coding '
Transaction Code NPDES No. Yr/Mo/Day Inspection Type Inspector Facility Type
N 5 NC0056855 02/10/30 C S 2
Remarks:
Inspection Work Days Facility Evaluation Rating BI QA Reserved...........
1.5 5 N N
Section B:Facility Data
Name and Location of Facility Inspected: Entry Time: Permit Effective Date:
Pharr Yarns Complex 46 2:44 pm 01/10/01
200 Saxony Drive
northeast of Lowell Exit Time/Date: Permit Expiration Date:
Gaston County,North Carolina 2:50 pm 05/01/31
02/10/30
Name(s)of On-Site Representative(s)/Title(s)/Phone No(s)/Fax No(s):
Mr.James Davis/Backup ORC/704-824-3551
Name and Address of Responsible Official: Title: Environmental Engineer/ORC
Mr.Mike Church
Pharr Yarns,Inc.
Post Office Box 1939 Phone No: Contacted?
McAdenville,North Carolina 28101-1939 704-824-3551 Yes
Section C:Areas Evaluated.During Inspection(Check only those areas evaluated)
X Permit X Flow Measurement X Operations&Maintenance Sewer Overflow
X Records/Reports X Self-Monitoring Program Sludge Handling/Disposal Pollution Prevention
X Facility Site Review Compliance Schedules Pretreatment Multimedia
X Effluent/Receiving Waters X Laboratory Storm Water Other:
Section D:Summary of Findings/Comments
See Attached Sheet(s) for Summary.
Name(s)and Signature(s)of Inspectors: Agency/Office/Telephone No: Date:
Wes Bell rhi v--p'e—+" NCDWQ/MOORESVILLE/[phone] 11/4/02
Date:
Signature of Management QA Reviewer: Agency/Office/Phone&Fax No: Date:
i
EPA Form 3560-3(Rev.9-94)Previous editions are obsolete

Pharr Yarns Complex 46
Page Two
The facility was last inspected by Wes Bell of this office on December 13,2001.
PERMIT:
The permit authorizes the continued discharge of condensate wastewater from textile
autoclaves and an air washer.
The current permit became effective on 10/1/01 and expires on 1/31/05.
RECORDS AND REPORTS:
Records and reports consisting of discharge monitoring reports (DMR's), calibration logs,
Operator-in-Responsible Charge (ORC)/daily operation log were reviewed at the time of the
inspection. The facility's records were in-depth and well organized.
FACILITY SITE REVIEW/OPERATIONS & MAINTENANCE:
The facility last reported a discharge in August 2000. According to the ORC,the lack of flow
was due to the facility's autoclaves not being in operation. The surrounding grounds were well
maintained. The facility is staffed with one Grade IV ORC. A certified back-up operator has been
designated and is available when the ORC is unable to visit the facility. The ORC and staff were
very knowledgeable of the treatment processes and equipment used at the facility.
LABORATORY:
The staff at the Pharr Yarns WWTP Laboratory (Certification#229) in McAdenville,INC.
perform the required analyses. The laboratory was not evaluated at the time of the inspection.Please
refer to Mr. Chet Whiting's (Division's Laboratory Certification Unit) Laboratory Certification
Maintenance Inspection report dated 5/14/02 for the inspection performed at the Pharr Yarns WWTP
laboratory on 3/19/02.
EFFLUENT/RECEIVING WATERS:
The facility was not discharging at the time of the inspection. The facility discharges into
an unnamed tributary to the South Fork Catawba River,which is a Class WS-V water in the Catawba
River Basin. The receiving stream was not evaluated at the time of the inspection.
SELF-MONITORING PROGRAM:
Self-monitoring reports were reviewed for the period October 2001 through July 2002,
inclusive. The facility did not report a discharge for the entire review period.
FLOW MEASUREMENT:
Instantaneous flow is measured by multiplying the known volume per autoclave (330
gallon/autoclave) by the number of discharges that occur.

Michael F. Easley
�pF wATFgo �A Governor
«L, William G. Ross,Jr.,Secretary
r MENR
North Carolina Department of Environment and Natural Resources
0 'C Kerr T. Stevens,Director
Division of Water Quality
February 28,2001
MIKE CHURCH
PHARR YARNS
P.O.Box 1939
McAdenville,NC 28101
Subject: Renewal Notice
NPDES Permit NC0056855
COMPLEX 46
Gaston County
Dear Permittee:
The subject permit expires on September 30,2001. North Carolina Administrative Code(15A NCAC 2H.0105(e))
requires that an application for permit renewal be filed at least 180 days prior to expiration of the current permit. If you have
already mailed your renewal application,you may disregard this notice.
To satisfy this requirement,your renewal package must be sent to the Division postmarked no later than April 5,2001.
Failure to request renewal of the permit by this date may result in a civil assessment of at least$500.00. Larger penalties may be
assessed depending upon the delinquency of the request.
If any wastewater discharge will occur after September 30,2001 (or if continuation of the permit is desired),the current
permit must be renewed. Discharge of wastewater without a valid permit would violate North Carolina General Statute 143-215.1
and could result in assessment of civil penalties of up to$25,000 per day.
If all wastewater discharge has ceased at your facility and you wish to rescind this permit,contact Bob Sledge of the
Division's Compliance Enforcement Unit at(919)733-5083,extension 547. You may also contact the Mooresville Regional
Office at(704)663-1699 to begin the rescission process.
Use the enclosed checklist to complete your renewal package. The checklist identifies the items you must submit with
the permit renewal application. If you have any questions,please contact me. My telephone number,fax number and e-mail
address are listed at the bottom of this page.
Sincerely,
Valery Stephens
Point Source Branch
cc: Central Files
. ` s Office, QJ ty;§ectio)a r
NPDES File
1617 Mail Service Center,Raleigh,North Carolina 27699-1617 919 733-5083,extension 520 (fax)919 733-0719
VISIT US ON THE INTERNET @ http-lh2o.enr.state.nc.us/NPDES e-mail:valery.stephensancmail.net

NPDES Permit NC0056855
PHARR YARNS
Gaston County
The following items are REQUIRED for all renewal packages:
❑ A cover letter requesting renewal of the permit and documenting any changes at the facility since
issuance of the last permit. Submit one signed original and two copies.
❑ The completed application form (copy attached), signed by the permittee or an Authorized
Representative. Submit one signed original and two copies.
❑ If an Authorized Representative (such as a consulting engineer or environmental consultant) prepares
the renewal package, written documentation must be provided showing the authority delegated to any
such Authorized Representative (see Part II.B.11.b of the existing NPDES permit).
❑ A narrative description of the sludge management plan for the facility. Describe how sludge (or other
solids) generated during wastewater treatment are handled and disposed. If your facility has no such
plan (or the permitted facility does not generate any solids), explain this in writing. Submit one signed
original and two copies.
The following items must be submitted ONLY by Tndustrial facilities discharging process
wastewater:
❑ Industrial facilities classified as Primary Industries (see Appendices A-D to Title 40 of the Code of
Federal Regulations, Part 122) must submit a Priority Pollutant Analysis (PPA) in accordance with 40
CFR Part 122.21. If the PPA is not completed within one week of April 5, 2001, submit the application
package without the PPA. Submit the PPA as soon as p o'sible after April 5,2001.
The above requirement does NOT apply to municipal or nonindustrial facilities.
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PLEASE NOTE:
Due to a change in fees effective January 1, 1999, there is no renewal fee required with your
application package.
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Send the completed renewal package to:
Ms. Valery Stephens
NC DENR / Water Quality / Point Source Branch
1617 Mail Service Center
Raleigh, NC 276'•9-1617