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NORTH" CAROLINA DEPARTMENT OF
ENVIRONMENT AND NATURAL RESOURCES
DIVISION' OF WATER QUALITY
FAYETTEVILLE REGIONAL OFFICE..
November 9, 2000
Mr. Carlton Williams
Swift Textiles, Inc.
200 North 13th Street
Erwin, NC 28339 "
SUBJECT: Compliance Evaluation Inspection
Swift Textiles, Inc. WWTP
NPDES Permit No. NC0001406
Harnett County
Dear Mr. Williams:
Enclosed is a copy of the Compliance Evaluation Inspection conducted
October 26.2000.
•
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 objective we should all be striving
for is NPDES permit compliance which in turn will provide preservation of our
receiving stream for generations to come.
With your facility closing permanently, please notify DWQ staff within 48
hours or the next working day when discharge will cease. DWQ staff would like to
perform a closeout inspection to ensure preservation of our receiving stream and
environment.
Please review the attached report. If you or your staff have any questions do
not hesitate to contact me at [phone].
S c rely
Belinda S. Henson
Environmental Chemist
/bsh
Enclosures
WC Se nOLS
225 GREEN STREET, SUITE 714 / SYSTEL 13LD. FAYETTEVILLE, NORTH CAROLINA 28301-5043
PHONE [phone] FAX [phone]
AN EQUAL OPPORTUNITY / AFFIRMATIVE ACTION EMPLOYER - 50% RECYCLED/10% 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: 001026
Inspector: S
/ Inspection Type: C
Facility, Type: 2 Reserved:
Facility Evaluation Rating: 4 BI: N QA: N
Section B: Facility Data
Name and Location of Facility Inspected:
Swift Textiles Inc. WWTP
Entry Time: 9:35am
Exit Time/Date: 1:10pm/001026
Name(s), Title(s) of On -Site Representative(s):
Billy Addison -(Certified Grade lV)-"ORC"
Martin Morris -(Certified Grade IV) -"Backup Operator"
Phone Number(s): [phone] ext. 6894
Name, Title and Address of Responsible Official:
Mr'. Carlton Williams, Plant Engineer
200 North 13th Street _
Erwin, NC 28339
Section C: Areas Evaluated During Inspection
Reserved:
Permit Effective Date: 970501
Permit Expiration Date: 010731
Contacted: no
(S = Satisfactory, M = Marginal, U = Unsatisfactory, N = Not Evaluated, N/A = Not Applicable)
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Section D: Summary of Findings/Comments:
1. The sulfuric acid tank located at the Headworks of the facility has a volume of 8000 gallons. The acid
is used for pH adjustment. Ammonia (Urea) has not been used recently for treating the wastewater.
2. The automatic bar screen appeared to be operational with all screenings disposed of through the county
landfill.
3. The grit removal system appeared to be operational with all grit disposed of through the county landfill.
4. The aeration basins appeared to be adequately treating the wastewater. All aerators were operational.
The most recent Mixed Liquor Suspended Solids (MLSS) result was 4500 mg/L and a Dissolved
Oxygen result of 4.0 mg/L. Polymer is added to the aeration basins to assist with solids settling in the
clarifiers.
5. The clarifiers appeared to be operating adequately. They appeared to be clean and well maintained. The
sludge depths were 5 feet in one and 4 feet in the other with a tank depth of 10 feet.
6. The effluent appeared to be free of solids.
7. A Sigma 8420 Dissolved Oxygen (DO) meter had been installed since the last inspection. The DO was
reading 11.5 mg/L at the time of the inspection with a water temperature of 65 degrees C. The DO meter
is located after the cascade aeration. The effluent flows through cascade aeration before it is discharged
directly to the Cape Fear River.
8. The effluent flow meter was calibrated May 16, 2000 by J S Dismuke. It is advisablefthat the flow meter
calibration document contain the % error before and after calibration in the future by the technician.
9. The effluent composite sampler refrigerator temperature was 1 degree C. The proper temperature for
samples during compositing is 0 - 4 degrees C.
10. The facility has 2 holding tanks for biosolids. The holding tanks have a capacity of 1 million gallons.
They tanks were approximately.1/z capacity of biosolids. Approximately 1 million gallons a month of
biosolids are land applied under permit # WQ 0006298. The land application permit allows 2000 dry
tons/year to 2880 acres.
11. The filter press is operational and a storage area for dewatered biosolids is on site. The filter press is
used during wet seasons when biosolids cannot be applied to land.
12. Flow from pipe #'002 is backwash water from the filters when they are cleaned at the water plant facility.
13. The following NPDES 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".
14. Laboratory records for the month January 2000 were reviewed and compared to Discharge Monitoring
Reports (DMRs). The records reviewed appeared to be accurate.
-continued-

15. A compliance evaluation analysis report for the period September 1999 through August 2000 did not
reveal any monthly violations.
16. As a reminder as per our Administrative Code Section: 15A NCAC 2B .0506(b)(3)(F)(i)-the date on
which collection of composite samples is commenced or data shall be entered onto the monitoring report
form on the date that has the greater number of hours in it. The following examples will assist you in
understanding the reporting date:
a. If the composite sample is started on Tuesday, October 3, 2000 at 9:OOAM and the sample is
withdrawn from the composite sampler on Wednesday, October 4, 2000 at 9:OOAM; the day
with the greater number of hours in it is Tuesday, October 3, 2000.
b. If the composite sample is started on Tuesday, October 3, 2000 at 6:OOPM and the sample is
withdrawn from the composite sampler on Wednesday, October 4, 2000 at 6:OOPM; the day
with the greater number of hours in it is Wednesday, October 4, 2000.
Name and Signature of Inspector
Belinda S. Henson U�
Agency/Office/Telephone Date
44e DENR/Fayetteville/[phone] 11 - � — 0 0
Name and Signature of Reviewer Agency/Office/Telephone
Paul E. Rawls %/ DENR/Fayetteville/[phone]
Action Taken
Regulatory Office Use Only
Compliance Status
Noncompliance
_Compliance
Date
KYT
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).
No N/A
(Yes) No
es ,No N/A 3. Adequate alarm system for power or equipment failure
Cep No N/A
es No N/A
No
es No
No
No
4. Sludge disposal procedures appropriate:
a: Disposal of sludge according to regulations
b. State approval for sludge disposal received.
N/A 5. All treatment units other than backup units in service.
FACILITY SITE REVIEW -
. Treatment units properly operated and maintained.
N/A 2. Standby power or other, equivalent provision provided. -Vo r (u m PS
available. 4, c4 1 l e u e I
aka{in ca11s
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Alai
N/A 6. Sufficient sludge disposed of to maintain treatment process equilibrium.
N/A 7. Adequate number of qualified operators on staff.
N/A 8. Established procedures available for training new employees.
No N/A 9. Adequate spare parts and supplies inventory maintained.
Yes
Yes GO
Yes
N/A
N/A
N/A
10. a. Hydraulic overflows and/or organic overloads 'experienced
b. Untreated'bypass discharge occurs during power failure
c. Untreated overflows occurred since last inspection.
es No N/A 11. Plant has general safety structures such as rails around or covers over
tanks, pits, or wells.
es No N/A 12. ,Plant is generally clean, free from open trash areas.

Page 2
13. Screening:
Yes No N/�' a. Manual
es No N/A b. Mechanical
Yes N/A c. Buildup of debris
es No N/A d. Screenings properly disposed of.
14. Grit Removal:
Yes agi N/A a. Excessive organic content in the grit chamber
Yes CDio N/A b. Excessive odors
Ye" No N/A c. Grit properly disposed of.
15. 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.
16. _ Trickling Filter:
Yes No IV/A� a. Trickling filter ponding(indicating clogged media)
Yes No N/A b. Leak at center column of trickling filter's distribution arms
Yes No N/A c. Uneven distribution of flow on trickling filter surface
Yes No N/A d. Uneven or discolored growth
Yes No N/A e. Excessive sloughing of growth
Yes No N/A f. Odor
Yes No N/A g. Clogging of trickling filter's distribution arm orifices
Yes No N/A h. Filter flies, worms, or snails.
17. Rotating Biological Contactors (RBC):
Yes No a. Development of white biomass 'on rotating biological contactor
media
Yes No N/A 'b. Excessive sloughing of growth
Yes No N/A c. Excessive breakage of rotating disks or shafts in RBC units
Yes No N/A d. Excessive breakage of paddles on brush aerators
Yes No N/A e. Shaft,bearing, drive gear, or motor failure on disk or brush aerators.

7
18.
N/A
• Yes N/A
Yes g N/A
Yes N/A
Yes (S-6) N/A
Yes No
Yes No
•
Yes No
Yes No N/A
Yes No_ N/A
Yes No N/A
20.
Yes (WO N/A
- Yes N/A
Yes. g) N/A
Yes N/A
Yes N/A
Yes N/A.
Yes (Ii3) N/A
Yes
Yes
Yes
r • Yes
• Yes
Yes
• Yes
• Yes
Yes
Yes
Yes
Yes
Yes
-Yes
Yes
Yes
Yes
r
Page' 3
Activated Sludge Basins/Oxidation Diiches
a. Dead spots
b. Failure of stirface aerators
c. Air rising in clumps
d. Dark foam-orbad color
• e. Thick billows -of white; sudsy foam
f . Air rising unevenly •
g. Excessive air leaks in compressed air piping.
Stabilization Ponds/Lagoons:
a. Excessive weeds including duckweed in stabilization ponds
bi Dead fish or aquatic organisnis
c. Buildup of' solids around influent pipe
d. Excessive scum on surface:
Secondary Clarifier:
a. Excessive gas bubbles on surface
b. • Unlevel overflow weirs
c. Weir blockage
d. Evidence of short circuiting
e. Excessive buildup of solids in center well of circularclarifier
f. , Pin floc in overflow
g. Ineffective scum rake
N/A h. Floating sludge on surface
i. Excessive high sludge blanket
&P N/A j. Clogged sludge withdrawal ports On secondary clarifier.
21. Filtration:
No /.:4). •_ a. Filter surface clogging
No • N/A • b. Short filter run
No N/A • _• c. Gravel displacement offilter Media
No .N/A d. Loss of filter media duringbackwashing
No N/A ' e. ReCyCled filter baCkWash Water in excess of 5 percent
No -N/A -f. Formation:of mudballs in filter media. •
No
No N/A
No N/A
No N/A
No N/A
No N/A
No N/A
No • N/A
22. Chlorination Unit: •_
a. Sludge buildup in contact chamber
b. Gas bubbles
• c. Floating scum and/or solids, „
d. Adequate ventilation of chlorine feeding room and storage area
e. • NIOSH-approved 30 minute -air pack
f.A1i standing chlorine cylinders chained in place
g: All personnel trained. in the use of chlorine
it Proper chlorine feed, storage, and reserve supply.

Page 4
Yes No /�A 23. Ultraviolet radiation disinfection present and in use.
24. Dechlorination:
Yes No a. Proper storage of sulfur dioxide cylinders
Yes No N/A b. Adequate ventilation of sulfur dioxide feeding room
Yes No N/A c. Automatic sulfur dioxide feed or feedback control not operating
properly. r
Yes OD N/A
Yes T' N/A
Yes CNd N/A
Yes Nb N/A
25. Aerobic Digester:
a. Excessive foaming in tank
b. Noxious odor
c. Mechanical aeration failure
d. .Clogging of diffusers.
26. Anaerobic Digester:
Yes No VIA) a. Floating cover tilting
Yes No N/A b. Gas burner operative •.
Yes No N/A c. Supernatant has a sour odor.
Yes No(1TA)
Yes No
Yes No . T
Yes No
Yes No?
(YCs) No N/A
No N/A
Yes No N/A
Yes No N/A
Yes No N/A
Yes No N/A
Yes N
Yes No N/A
Yes No N/A
27. Sludge Drying and/or disposal:
a. Poor sludge distribution on drying beds
b. Vegetation in drying beds
c. Dry sludge remaining in drying beds
d. Dry sludge stored on site
e. Filtrate from sludge drying beds returned to front of plant
f. Approved disposal site for the sludge
g. Sludge land applied.
28. Filter Press: 10/
a. High level of solids in filtrate from filter presses or vacuum filters
b. Thin filter cake caused by poor dewatering
c. Sludge buildup on belts and/or rollers of filter press
d. Excessive moisture in belt filter press sludge cake.
29. Polishing Ponds or Tanks:
a. Objectionable odor, excessive foam, floating solids, or oil sheens on
water surface
b. Solids or scum accumulations in tank or at side of pond
c. Evidence of bypassed polishing ponds or tanks because of low
capacity.

Page 5
30. Plant Effluent:
Yes CM N/A a. Excessive suspended solids, turbidity, foam, grease, scum, color, and
other macroscopic particulate matter present
Yes (o N/A b: Potential toxicity (dead. fish;' dead plant at discharge)
Yes ; No N/A c. Outfall discharge line easily accessible.
No N/A
No N/A
Yes co N/A
Yes -N N/A
Yes No N/A
Yes No N/A
YesOD N/A
No N/A
Yes No N/A
)No N/A
No N/A
Yes No N/A
No N/A
Yes No N/A
31. Flow Measurement:
a. Proper placement of flow measurement device
b. Flow meter calibrated
c: Buildup of solids in flume or weir
d. Broken or cracked flume or weir ,
e. Properly functioning magnetic flowmeter
f. Clogged or broken stilling wells
g. Weir plate edge corroded or damaged
h. System capable of measuringmaximum flow
i. Flow measurement error less than 10%.
32. Sampling:
a. Sampling and analysis completed on parameters specified by permit
b. Samples refrigerated during compositing
c. Composite sample temperatures maintained at 0 to 4 degrees Celsius
during sampling
d. Contract laboratory used for sample analysis
e. Composite samples obtained are flow proportional.
' RECORDKEEPING'AND REPORTING
Ye)No N/A 1. Records and reports maintained as required by permit.
es No N/A 2. All required information available, complete, and current.
es No N/A 3'. Records maintained for 3 years and all sludge records maintained for 5
years.
6-Q 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
Yes No N/A b. Name of individual performing sampling
(Yes)No N/A c. Results of analyses and calibration
No N/A d: Dates of analyses
No N/A e. Name of person performing analyses:

Yes No , N/A
• No N/A
(Yei No N/A
Yes No
Page 6
6. Monitoring records adequate and include:
a. Monitoring charts kept for 3 years
b. Flowmeter calibration records kept for 3. years.
7. Laboratory equipment calibration and maintenance records adequate.
8. BOD incubator temperature maintained at 20 +/- 1 Degrees Celsius
and the temperature maintained in a log fo`r every day of operation.
Yes No N/A )' 9. Fecal coliform incubator maintained at 44.5 +/- 0.2 Degrees
Celsius and the temperature maintained in a log for every day of
operation.
Yes No_ N/A
'triltNo N/A
We7 No N/A
Yes No
Yes No : `►T�I
No N/A
&s No N/A
No N/A
" 10. Plant records adequate and include:
a. O. & M Manual
b. "As -built" engineering drawings
c. Schedules and dates of equipment maintenance repairs
d. Equipment data cards.
11. Permittee is meeting compliance schedule.
12.. DMRs complete and include all NPDES permit required parameters.
13.- ORC visitation logs available and current.
14. ORC certified at a level equal to or greater'than the classification of
the wastewater facility.
►�� No N/A 15. Backup Operator certified at one level less than the classification of
the wastewater facility or greater.
Yes No N/A 16'. Current copy of the complete NPDES permit on site.
No N/A 17. Facility description verified as contained in NPDES permit.
Revised 7/11/Q0
by Belinda Henson
1

INSPECTION REPORT
UPDATE OPTION: TRX: 5IF KEY: NC0001406INSCEI 001026
SYSMSG: *** DATA ADDED SUCCESSFULLY ***
PERMIT-=- NC0001406 REG/COUNTY-- 06 HARNETT
FACILITY-- SWIFT TEXTILES (ERWIN MILLS) LOC-- ERWIN
INS TYPE
CEI
NEXT PLANNED
INSPECTION INSPECTED BY:
DATE: 001026 HSB
REPORT INSPECTION DMR RESPONSE RECEIVED
DATE STATUS STATUS DUE DATE DATE
001109 C C
COMMENTS: