NC0001406_Inspection_20011004

NCDENR
North Carolina Department of Environment and Natural Resources
Michael F. Easley, Governor
Mr. Norman Averey
-Swift Textiles, Inc.
200 North 13th Street
Erwin, NC 28339
October 4, 2001
SUBJECT: Compliance Evaluation Inspection
Swift Textiles, Inc. WWTP..
NPDES Permit No... NC0001406
Harnett County
William G. Ross Jr., Secretary
Gregory. J. Thorpe, Ph.D.
Acting Director
Division of Water Quality
Dear Mr. Averey:
Enclosed is a copy of the Compliance Evaluation Inspection conducted Septeniber'25, 2001.
The ,manufacturing facility for Swift Textiles . has„closed permanently and the only wastewater
discharging into the wastewater plant is domestic from residential areas in the Town of Erwin. As
part of the inspection a tour of the Wastewater Treatment Plant was conducted. All observations,' and
recommendations • are in Part D. Summary of Findings/Comments of this inspection report. The
cooperation of Mr. Waldo.Faircloth, former head boiler operator was appreciated. As a reminder
please notify DWQ staff within 48 hours or the next working day when discharge will cease. DWQ•
staffwould like to perform a closeout inspection,to ensure preservation of our Waters of the State.
Please review the attached report. If you or your staff have any questions do not hesitate to
contact me at [phone].
Sincerely,
Belinda S. Henson
Environmental Chemist
• /bsh
Enclosures
cc: Mr. Billy Addison, ORC/Public Works Director (Town of Benson)
Central Files •
FRO Files
Fayetteville Regional Office
225 Green Street- Suite 714, Fayetteville, North Carolina .28301-5043
'Phone: [phone] FAX: [phone] Internet: www.enr.state.nc.us/ENR
An Equal Opportunity\ Affirmative Action Employer — 50% Recycled-110% Post Consumer Paper

NPDES COMPLIANCE INSPECTION REPORT
North Carolina Division of Water Quality
Fayetteville Regional Office
Section A. National Data System Coding
Transaction Code: N NPDES NO. NC0001406 Date: 010925 Inspection Type: C
Inspector: S Facility Type: 2 Reserved:
Facility Evaluation Rating: 4 BI: N QA: N Reserved:
Section B: Facility Data
Name and Location of Facility Inspected:
Swift Textiles Inc. WWTP
Entry Time: 9:45am Permit Effective Date: 010301
Exit Time/Date: 11:10pm/010925 Permit Expiration Date: 020331
Name(s), Title(s) of On -Site Representative(s):
Waldo Faircloth - "Former Head Boiler Operator"
Phone Number(s): [phone]
Name, Title and Address of Responsible Official:
Mr. Norman Avery
200 North 13th Street
Erwin, NC 28339
Contacted: yes
Section C: Areas Evaluated During Inspection
(S = Satisfactory, M = Marginal, U = Unsatisfactory, N = Not Evaluated, N/A = Not Applicable)
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Mr. Avery
Page 3
October 4, 2001
Section D: Summary of Findings/Comments:
1. The influent flow is pumped into the plant by variable pace drive pumps which operate when the flow
reaches a certain level they begin pumping. The two (2) pumps alternate.
2. The automatic bar screen and grit removal system appeared to be operational. The screenings and grit
are presently stored in a compartment behind the bar screen/grit removal system. The screenings and
grit should be placed in a container and properly disposed of.
3. The two aeration basins were operational. Plans are to shut one basin down soon and operate the facility
with one aeration basin: -
4. Clarifier #1 is not operating due to the decreased amount of flow into the plant. Clarifier #2 is in.
operation with < (less than) 1 foot of sludge depth: At the time of the inspection there did not appear
to be an effluent flow over the weirs. The effluent flows. through cascade aeration before it is
discharged directly to the Cape Fear River.
5. The facility collects a composite sample over an 8 hour period Monday .through Friday and it is placed
in a refrigerator for storage until they are shipped to the commercial laboratory (Environment 1) for
analyses of the NPDES permit required parameters.
6. The Polysonics effluent flow meter was calibrated October 27, 2000 by J S Dismuke. It is advisable that
the flow meter calibration document contain the % error before and after calibration in the future by the
technician.
7. The, facility has a holding tank for biosolids and two (2) sludge thickening tanks. The holding tank has
approximately 1/4 capacity of sludge. One thickening tank is empty and the other has approximately .
250,000 gallons of sludge in it. .Records for sludge disposal revealed that the most recent haul was
April 2001; with '775,000 gallons of sludge that were land applied by the contract. company Synagro
under permit # WQ 0006298. Plans . are to remove all solids, from the thickening tank and use the
holding tank for sludge.
8. . The filter press is operational and onsite but does not appear to have been'utilized recently..
9. A discharge from pipe # 002 has ceased with the closing of the water plant facility. The discharge from
this pipe was backwash water from the filters.
10. The followingNPDES permit required parameters are analyzed by facility staff: pH, Temperature, and
Dissolved Oxygen. The commercial laboratory "Environment 1" analyzes all other required parameters
with the exception of the Toxicity which is completed by the commercial laboratory "Tritest".
11. Laboratory records for the month March. and April2001, were reviewed and compared to Discharge
Monitoring Reports (DMRs). The records reviewed appeared to be accurate.

Mr. Avery
Page 4
October 4, 2001
12. A compliance evaluation analysis report for the period August 2000 through July 2001 did not reveal
any monthly violations.
Name and Signature of Inspector
Agency/Office/Telephone Date
Belinda S. Henson DENR/Fayetteville/(9 10)4 8 6-15 41
.(6,Ly,c46 x 46,sae-yo
Name and Signature of Reviewer Agency/Office/Telephone
Paul E. Rawls
Action Taken
DENR/Fayetteville/(9 10)48 6-15 41
Regulatory Office Use Only
Compliance Status
Noncompliance
_Compliance
-z(-G/
Date
Date

•
Section D: Summary of Findings/Comments
Brief Facility Description:-
2.5 MGD WWTP consisting of influent pH adjustment, influent ammonia nitrate feed, automatic
mechanical bar screen,mechanical grit removal, influent recording flow measurement. parallel
aeration basins; polymer feed system to assist clarification,dual clarifiers, effluent recording flow
measurement, sludge storage tank, belt type -filter press, polymer storage and two sludge
thickening/mixer tanks, pivoting elevated sludge cake conveyor. and sludge storage area (outfall
001). Discharge filter backwash water from alum sludge settling basins (outfall 002).
FACILITY SITE REVIEW
No N/A 1. Treatment units properly operated and maintained.
No N/A 2. Standby power or other equivalent provision provided. For -1-'n � z 1+
No N/A 3.. Adequate alarm system for power or equipment failure available.
4. Sludge disposal procedures appropriate:
No N/A a. Disposal of sludge according to regulations
No N/A b. State approval for sludge disposal received.
No N/A 5. Sufficient sludge disposed of to maintain treatment process equilibrium.
es No . N/A 6. The ORC and Backup Operator are officially designated with
NCDENR/DWQ Training and Certification Unit.
Yes No N/A . 7. Adequate spare parts and supplies inventory maintained.
No N/A
Plant has general safety structures such as rails around or covers over
tanks, pits, or wells.
No N/A 9. Plant is generally clean, free from open .trash areas.
•
:10. Screening: -
Yes No a. Manual
No N/A. - b. Mechanical
Yes es) N/A c. Buildup of debris
Yes ®o N/A d. Screenings properly disposed of.
Yes
Yes
Yes
No
11. Grit Removal:
N/A .. a. Excessive organic content in the grit chamber
N/A b. Excessive odors
N/A c: Grit properly disposed of
fci►vi pS

Yes No
Yes No N A
Yes No N/A
Yes No N/A
Page 2
12. Primary clarifier:
Yes No a. Excessive gas bubbles
Yes No N/A b. Black and odorous wastewater
Yes No N/A c. Poor suspended solids removed
Yes No N/A d. Excessive buildup of solids in center well of circular clarifier
Yes No N/A e. Weirs level
Yes No N/A f. Weir blockage
Yes No N/A g. Evidence of short circuiting
Yes No N/A h. Lack of adequate scum removal
Yes No N/A i. Excessive floating sludge
Yes No N/A j. Broken sludge scraper.
Yes No A.
Yes No /A
Yes No N/A
Yes No N/A
Yes No N/A
Yes No N/A
Yes No . N/A
Yes No N/A
13. Trickling Filter:
a. Trickling filter ponding(indicating clogged media)
b. Leak at center column of trickling filter's distribution arms
c. Uneven distribution of flow on trickling filter surface
d. Uneven or discolored growth
e. Excessive sloughing of growth
f. Odor
g. Clogging of trickling filter's distribution arm orifices
h. Filter flies, worms, or snails.
14. Activated Sludge Basins/Oxidation Ditches:
Yes N/A a. Dead spots
Yes �Io N/A b. Failure of surface aerators
Yes ' N/A c. Air rising in clumps
Yes N/A d. Dark foam or bad color
Yes (EDA e. Thick billows of white, sudsy foam
Yes No l f. Air rising unevenly
Yes No A g. Excessive air leaks in compressed air piping.
15. Stabilization Ponds/Lagooris: •
a. Excessive weeds including duckweed in stabilization ponds
b. Dead fish or aquatic organisms
c. Buildup of solids around influent pipe
d. Excessive scum on surface.

Page 3
Yes (ad) N/A
Yes OD N/A
Yes
Yes
Yes
Yes
Yes
• .Yes
Yes
Yes
Yes No
Yes No
Yes No
Yes No
Yes No
Yes No
N/A
N/A
N/A
N/A
N/A
N/A.
N/A
N/A
N/A
N/A
N/A
N/A
•
16. Secondary Clarifier:
• a. Excessive gas bubbles on surface
b. Level overflow weirs
c. Weir blockage
•d. Evidence of short circuiting ,
e. Excessive buildup of solids in center well of circular clarifier
f. Pin floc in overflow •
g. • Effective scum rake,
h. Floating sludge on surface
i. Excessive high.sludge blanket .•
. jClogged sludge-withclraWal ports on secondary clarifier.
••
17. Filtration
a. Filter surface,clOgging
• b. Short filter run
c. • Gravel displacement of -filter niedia.
d. 'Loss of filter media during backwashing •
:e. Recycled filter backWash waterin excess of 5,percent
f.. Formation of mudballs,in filter media. .
18.. Chlorination Unit: •
Yes No OA) a. Sludge buildup in contact chamber.
Yes No N/A • " b. Gas bubbles
Yes No N/A • c. • Floating scum and/or solids
Yes No N/A • cl: Adequate ventilation of chlorine feeding room and storage area
Yes No N/A • e. NIOSH-approved 30 minute air pack
Yes No N/A • f All standing chlorine cylinders chained in place
Yes No N/A •g. All personnel trained in the use Of chlorine „
Yes No N/A • h. Proper chlorine feed, storage, and reserve supply.
Yes No 19. Ultraviolet radiation disinfection present and in use,
20. DechlOrination:
Yes No j., • a. Proper storage of sulfur dioxide cylinders • •
,
Yes NO N/A 6: Adequate ventilation of sulfur dioxide feeding room
Yes No N/A. c. Automatic sulfur dioxide feed Or feedback control operating
properly:
21. : Aerobic Digester: •
Yes (M N/A a. Excessive foaming in tank
Yes CD N/A b. NoxiOus odor
• Yes diN • to c. Mechanical aeration failure
Yes 4:0 •d. Clogging of diffusers;

Page 4
Yes No
Yes No N/A
22. Anaerobic Digester:
a. Floating cover tilting
b. Gas burner operative
23. Sludge Drying and/or disposal:
Yes No NT a. Poor sludge distribution on drying beds
No N/A b. Vegetation in drying beds
Yes N/A c. Dry sludge remaining in drying beds
Yes QLSO N/A d. Dry sludge stored on site
Yes No N/A e. Filtrate from sludge drying beds returned to front of plant
Yes N( N/A f. Sludge disposal through county landfill.
Ye No N/A g. Sludge land applied.
24. Filter Press: (16�u*' 4'3 e �' of
Yes No N/A , a. High level of solids in filtrate from filter presses or vacuum filters
Yes No N/A b. Thin filter cake caused by poor dewatering
Yes No N/A c. Sludge buildup on belts and/or rollers of filter press
Yes No N/A d. Excessive moisture in belt filter press sludge cake.
25. Polishing Ponds or Tanks:
Yes No N/ a. Objectionable odor, excessive foam, floating solids, or oil sheens on
water surface
Yes No N/A b. Solids or scum accumulations in tank or at side of pond
Yes No N/A c. Evidence of bypassed polishing ponds or tanks because of low
capacity.
26. Plant Effluent: no -Vb.) a.+- c'S 4h
Yes No N/A a. Excessive suspended solids, turbidity, foam, grease, scum, color, and
other macroscopic particulate matter present
Yes No N/A b. Potential toxicity (dead fish, dead plant at discharge)
Cal No N/A c. Outfall discharge line easily accessible.
• 27. Flow Measurement: •
as No N/A a. Proper placement of flow measurement device
No N/A b. Flow meter calibrated
Yes a N/A c. Buildup of solids in flume or weir
Yes 'Gil) N/A d: Broken or cracked flume or weir
Yes No e. Clogged or broken stilling wells
Yes No N/A f. Weir plate edge corroded or damaged
Yes No N/A g. Flow measurement error less than l 0%.

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

Page 6
Yes No
Yes No
Yes No
Yes No N/A
Yes No N/A
No N/A
Yes No N/A
Yes No
11. The NPDES permit required parameter Total Chlorine Residual is
analyzed by approved method.
12. BOD incubator temperature Maintained at 20 +/- 1 Degrees Celsius
and the temperature maintained in a log for every day of operation.
13. Fecal coliform incubator maintained at 44.5 +/- 0.2 Degree Celsius and
the temperature maintained in a log for every day of operation.
14. Plant records adequate and include:
a. 0 & NI Manual
b. "As -built" engineering drawings
c. • Schedules and dates of equipment maintenance repairs
d. Equipment data cards.
15. Permittee is meeting compliance schedule.
No N/A 16. DMRs complete and include all NPDES permit required parameters.
Yes N/A 17. The facility has a permitted flow greater than 5 MGD and is required
to operate seven days per week 24 hours a day.
Ye No N/A 18. ORC visitation logs available and current.
CY6 No N/A 19. ORC certified at a level equal to or greater than the classification of
the wastewater facility.
Yes No N/A. 20. Backup Operator certified at one level less than the classification of
the wastewater facility or greater.
Yes gDN/A 21. Current copy of the complete NPDES permit on site.
•
No N/A . - 22. Facility description verified as contained in NPDES permit.
Yes V) N/A 23. Facility analyzes process control parameters for example: 11/MSS,
MCRT, Settleable Solids and others that are applicable.
Yes No
Revised 7/16/01
by Belinda Henson
24. Industrial Waste Surveys (IWS) sent to all possible Significant
Industrial Users (Sills) within the last five years (especially new
industries).

INSPECTION REPORT
UPDATE OPTION: TRX: 5IF KEY: NC0001406INSCEI 010925
SYSMSG: *** DATA ADDED SUCCESSFULLY ***
PERMIT--- NC0001406 REG/COUNTY-- 06 HARNETT
FACILITY-- SWIFT TEXTILES INC-ERWIN MILLS LOC-- ERWIN
INS TYPE
CEI
NEXT PLANNED
INSPECTION INSPECTED BY:
DATE.: 010925 HSB
REPORT INSPECTION DMR- RESPONSE RECEIVED
DATE STATUS STATUS DUE DATE DATE
011004 C C
COMMENTS: