NC0004812_permit issuance_20020614

NPDES DOCYNENT SCANNINL COVER SKEET
NPDES Permit:
NC0004812
Document e:
ermit Issuance
aste
oa
Allocation
Authorization to Construct AtC
Permit Modification
Compliance / Enforcement
Permit History
Date Range:
Correspondence
Document Date:
00e, ly ZDZ�,
THIS DOCUHENT IS PRIMPED ON REUSE PAPER IOMORE ANY COMPEMP ON THE
REVERSE SIDE

1
State of North Carolina
Department of Environment
and Natural Resources
Division of Water Quality
Michael F. Easley, Governor
William G. Ross, Jr., Secretary
Alan W. Klimek, P.E., Director
June 14, 2002
Mr. Mike Church
Pharr Yarns, Inc.
P.O. Box 1939
McAdenville, North Carolina 28101
NCDENR
NORTH CAROLINA DEPARTMENT OF
ENVIRONMENT AND NATURAL RE50URCE5
Subject: Issuance of NPDES Permit NC0004812
Pharr Yarns WWTP
Gaston County
Dear Mr. Church:
Division personnel have reviewed and approved your application for renewal of the
subject permit. Accordingly, we are forwarding the attached NPDES discharge permit. This
permit is issued pursuant to the requirements of North Carolina General Statute 143-215.1
and the Memorandum of Agreement between North Carolina and the U.S. Environmental
Protection Agency dated May 9, 1994 (or as subsequently amended).
The following changes have been made from your draft permit:
The COD limit has been changed. In the original draft, no allocation was made
for the domestic component of your wastestream. Since this component forms
such a large portion of your total wasteflow, the Division feels it is appropriate to
give a COD allocation for your domestic waste. Based upon data submitted to the
Division on December 10, 2001, a COD limit based upon site -specific factors and
Best Professional Judgement (BPJ) has been assigned.
The description of your treatment facilities has been amended in accordance
with the description you submitted on September 5, 2001.
Please also review the requirements associated with color, as described in Parts A.
(1.), A. (2.) and A. (6.). Due to the low color in your effluent, your facility has been classified
as a Tier 1 facility under the North Carolina Color Permitting Policy, and is subject to any
conditions stipulated in that policy.
If any parts, measurement frequencies or sampling requirements contained in this
permit are unacceptable to you, you have the right to an adjudicatory hearing upon written
request within thirty (30) days following receipt of this letter. This request must be in the
form of a written petition, conforming to Chapter 150B of the North Carolina General
Statutes, and filed with the Office of Administrative Hearings (6714 Mail Service Center,
Raleigh, North Carolina 27699-6714). Unless such demand is made, this decision shall be
final and binding.
1617 Mail Service Center, Raleigh, North Carolina 27699-1617 Telephone [phone] FAX [phone]
An Equal Opportunity Affirmative Action Employer Visa us ON THE INTERNET @ hgpJ/h2o.encstate.nc.us/NPOES

Please note that this permit is not transferable except after notice to the Division.
The Division may require modification or revocation and reissuance of the permit. This
permit does not affect the legal requirements to obtain other permits which may be required
by the Division of Water Quality or permits required by the Division of Land Resources, the
Coastal Area Management Act or any other Federal or Local governmental permit that may
be required.
If you have any questions concerning this permit, please contact Natalie Sierra at
telephone number [phone], extension 551.
Sincerely,
ORIGINAL SIGNED BY
SUSAN A. WILSON
Alan W. Klimek, P.E.
cc: Central Files
Mooresville Regional Office/Water Quality Section
NPDES Unit
Technical Assistance & Certification Unit
Aquatic Toxicology Unit
DEH
Mr. Roosevelt Childress, EPA Region IV
Ms. Donna Lisenby, Catawba Riverkeeper
2295 Starnes Road
Edgemoor, SC 29712
Mr. Ron Bryant Catawba River Foundation
P.O. Box 481915
Charlotte, NC 28269

a
Permit NC0004812
STATE OF NORTH CAROLINA
DEPARTMENT OF ENVIRONMENT AND NATURAL RESOURCES
DIVISION OF WATER QUALITY
PERMIT
TO DISCHARGE WASTEWATER UNDER THE
NATIONAL POLLUTANT DISCHARGE ELIMINATION SYSTEM
In compliance with the provision of North Carolina General Statute 143-215.1, other lawful
standards and regulations promulgated and adopted by the North Carolina Environmental
Management Commission, and the Federal Water Pollution Control Act, as amended,
Pharr Yarns, Incorporated
is hereby authorized to discharge wastewater from a facility located at the
Pharr Yarns Wastewater Treatment Plant
147 Willow Drive
McAdenville
Gaston County
to receiving waters designated as the South Fork Catawba River in the Catawba
River Basin
in accordance with effluent limitations, monitoring requirements, and other
conditions set forth in Parts I, II, III and IV hereof.
This permit shall become effective July 1, 2002.
This permit and authorization to discharge shall expire at -midnight on January 31, 2005.
Signed this day June 14, 2002.
ORIGINAL SIGNED BY
SUSAN A. WILSON
Alan W. Klimek, P.E., Director
Division of Water Quality
By Authority of the Environmental Management Commission

i
Permit NC0004812 �..
SUPPLEMENT TO PERMIT COVER SHEET
Pharr Yarns, Inc. is hereby authorized to:
1. Continue to operate an existing 1.0 MGD wastewater treatment facility for the
treatment of industrial and domestic wastewater consisting of an aeration basin,
two clarifiers with alum and polymer addition, mixed media pressure filters, an
aerobic digester, sludge thickening, dewatering belt press and chlorine
disinfection located at Pharr Yarns Wastewater Treatment Plant, 147 Willow
Drive, McAdenville in Gaston County, and
2. Discharge from said treatment works at the location specified on the attached
map into the South Fork Catawba River, which is a classified WS-V waterbody in
the Catawba River Basin.
It is agreed that NPDES permit limits for 1-MGD will become effective upon
achievement of both of the following conditions:
The monthly average effluent flow exceeds 0.5-MGD for
the first time
Pharr Yarns, Inc. submits to DWQ's NPDES and Point
Source Compliance and Enforcement Units a certified
letter within 30 days following the first month that the
average monthly effluent flow from the Pharr Yarns WWTP
exceeds 0.5-MGD.

•
t iCe
! k ' 'f�i • l �
"1 1 rlli f / /+�/ r•V1k f"]
o
/�/� ��� !,�•� Yam.. .,1. ' t�Sr r r • r • � >�err'`
f1/ � �•rr � , l• \,,'�/ , � „� � .. � a s+ , r Syr
�� -r\l `'\\ +• �..:
Aj
/ •r V.[ / I..J11 J ••
r , ■ r
i • i .� V4.1
■ .1.
1 R 1 • ,.) rr.,
NC0004812- Pharr Yarns, Inc.
Facility
j
Latitude: 35015'39" Sub -Basin: 03-08-36���`
Location
Longitude: 81004'38"rR
uad #: F14SE/Mount Holly, NC
Stream Class: WS-V
Receivine Stream: South Fork Catawba River
North
Pharr Yams, Inc.
Gaston County
Permitted Flow: 1.0 MGD
NC0004112

Perna t NC0004812
A. (1.) "EFFLUENT LIMITATIONS AND MONITORING REQUIREMENTS — FINAL
During the period beginning on the effective date of this permit and lasting until the first time the monthly
average flow exceeds 0.5-MGD, the Permittee is authorized to discharge from outfall 001. Such discharges
shall be limited and monitored by the Permittee as specified below: r
:EFFLUENT
CHARACTERISTICS'
LIMITS
MONITORING REQUIREMENTS =
Monthly Avera9eLT,
Dally Maximum
Mfsurement
�'Frequency
, Sample
Type
Sample Location,
Flow
0.5 MGD
Continuous
Recording
Influent or Effluent
BOD5, 200C
106.5 lbs/day
203.5 lbs/day
Weekly
Grab
Effluent c
Total Suspended Residue
130.1 lbs/day
307.3 lbs/day
Weekly
Grab
Effluent
COD
590.3 lbs/day
1430.7 lbs/day
Weekly
Grab
Effluent
Sulfide
0.5 lbs/day
2.3 lbs/day
Weekly
Grab
Effluent
Phenols
0.3 lbs/day
1.2 lbs/day
Weekly
Grab
Effluent
Total Chromium
0.3 lbs/day
1.2 lbs/day
Weekly
Grab
Effluent
Fecal Coliform (geometric mean)
200/100 ml
400/100 ml
Weekly
Grab
Effluent, Upstream,
Downstream'
NH3-N
Weekly
Composite
Effluent
Dissolved Oxygen
Weekly
Grab
Effluent, Upstream,
Downstream'
H2
Weekly
Grab
Effluent
Total Residual Chlorine
Weekly
Grab
Effluent
Temperature
Daily
Grab
Effluent
Temperature
Weekly
Grab
Upstream,
Downstream
Conductivity
Weekly
Grab
Effluent, Upstream,
Downstream'
Colors
Monthly
Composite
Effluent
Colors
Monthly
Grab
Upstream,
Downstream
Total Nitrogen
(NO2 + NO3 + TKN)3,4
No Effluent Limitation (mg/L)
No Effluent Limitation (lb/month) (3)
13,698 Ib/year (annual mass loading) (3,4)
Weekly
Composite
Effluent
Monthly
Calculated
Effluent
Annually
(Calculated)
Effluent
Total Phosphorus3,4
No Effluent Limitation (mg/L)
No Effluent Limitation (lb/month) (3)
1522 lb/year (annual mass loading) (3.4)
Weekly
Composite
Effluent
Monthly
Calculated
Effluent
Annually
I
(Calculated)
Effluent
Chronic Toxiciv
I I
Quarterly
Composite
Effluent
Notes:
1 Sample locations: Upstream - upstream 50 feet or more above the discharge point; Downstream - downstream at
Highway 7 bridge. Instream monitoring shall be conducted 3/week from June through September and once per week
the remainder of the year. i
2 The pH shall not be less than 6.0 standard units nor greater than 9.0 standard units
3 The annual mass loading for total nitrogen and total phosphorus for Outfall 001 shall be monitored and calculated as
prescribed in Part A.(5.).
4 ' The annual mass loading limit for total nitrogen and total phosphorus shall become effective on July 1, 2003
5 See Special Condition A.(6.) for more information on the permit requirements associated with color. Effluent color
samples shall be taken year round on a monthly basis. Instream sampling shall be performed on a. monthly basis from
April through October.
6 Chronic toxicity (Ceriodaphnia, P/F test at 0.62%) shall be performed in January, April, July and October. See Part
A.(3.)
There shall be no discharge of floating solids or visible foam in other than trace amounts.

Permit NC0004812
A.(2.), EFFLUENT LIMITATIONS AND MONITORING REQUIREMENTS- FINAL
During the period beginning on the month -following the first time the monthly average flow exceeds 0.5-
MGD and lasting until permit expiration, the Permittee is authorized to discharge from outfall 001. Such
discharges shall be limited and monitored by.the Permittee as specified below:
EFFLUENT
CHARACTERISTICS
LIMITS
MONITORING. REOU(REMENTS
Monthly Average
IDaity Maximum
Measurement
Frequent
Sample
'.T w
Sample'Locationt
Flow
1.0 MGD
Continuous
Recording
Influent or Effluent
BOD5, 200C
197.8 lbs/day
340.5 lbs/day
3/Week
Grab
Effluent
Total Suspended Residue
221.4 Ib§/day
444.3 lbs/day
3Meek
Grab
Effluent
COD
590.3 lbs/day
11430.7 lbs/day
3Meek
Grab
Effluent
Sulfide
0.5 lbs/day
2.3 lbsiday
Weekly
Grab
Effluent
Phenols
0.3 lbs/day
1.2 lbs/day
Weekly
Grab
Effluent ,
Total Chromium
0.3 lbs/day
1.2 lbs/day
Weekly
Grab
Effluent
Fecal Coliform (geometric mean)
2001100 ml
400/100 ml
3/Week
Grab
Effluent, Upstream,
Downstream'
NH3-N
3/Week
Composite
Effluent
Dissolved Oxygen
3/Week
Grab
Effluent, Upstream,
Downstream'
H2
3/Week
Grab
Effluent
Total Residual Chlorine
3/Week
Grab
Effluent
Temperature
Daily
Grab
Effluent
Temperature
3/Week
Grab
Upstream,
Downstream
Conductivity
3/Week
Grab
Effluent, Upstream,
Downstream'
Colors
Monthly
Composite
Effluents
Colors
Monthly
Grab
Upstream,
Downstreams
Total Nitrogen
(NO2 + NO3 + TKN)3.4
No Effluent Limitation (mg/L)
No Effluent Limitation (Ib/month) (3)
27397 lb/year (annual mass loading) (3.4)
Weekly
Composite
Effluent
Monthly
Calculated
Effluent
Annually
( Calculated
a,Effluent
Total Phosphorus3,4
No Effluent Limitation (mg/L)
No, Effluent Limitation (lb/month) (3)
3044 lb/year (annual mass loading) (3.4)
Weekly
Composite
Effluent
Monthly
Calculated
Effluent
Annually
(Calculated)
Effluent
Chronic Toxicity6
Quarterly
Composite
Effluent
Notes:
1 Sample locations: Upstream - upstream 50 feet or more above the discharge point; Downstream - downstream at
Highway 7 bridge. Instream monitoring shall be conducted 3/week from June through September and once per week
the remainder of the year.
2 The pH shall not be less than 6.0 standard units nor greater than 9.0 standard units
3 The annual mass loading for total nitrogen and total phosphorus for Outfall 001 shall be monitored and calculated as
prescribed in Part A.
4 The annual mass loading limit for total nitrogen and total, phosphorus shall become effective on July 1, 2003
5 See Special Condition A. (6.) for more information on the permit requirements associated with color. Effluent color
samples shall be taken year round do a monthly basis. Instream sampling shall be performed on a monthly basis from
April through October. _
6 Chronic toxicity (Ceriodaphnia, P/F test at 1.2%) shall be performed in January, April, July and October. See Part A.(4.)
There shall be no discharge of floating solids or visible foam in other than trace amounts.

Permit NC0004812'
A. (3.) CHRONIC TOXICITY MONITORING/LIMIT — 0.5-MGD "'
The effluent discharge shall at no time exhibit observable inhibition of reproduction or significant
mortality to Ceriodaphnia dubia at an effluent concentration of 0.62%.
The permit holder shall perform at a minimum, puarterlu monitoring using test procedures outlined
in the "North Carolina Ceriodaphnia Chronic Effluent Bioassay Procedure," Revised February:. 1998,
or subsequent versions or "North Carolina Phase II Chronic Whole Effluent Toxicity Test Procedure
(Revised -February 1998) or subsequent versions. The tests will be performed during the months of
January, April, July and October. Effluent sampling for this testing shall be performed at the
NPDES permitted final effluent discharge below all treatment processes.
If the test procedure performed as the first test of any single quarter results in a failure or ChV below
the permit limit, then multiple -concentration testing shall be performed at a minimum, in each of the
two following months as described in "North Carolina Phase II Chronic Whole Effluent Toxicity Test
Procedure" (Revised -February 1998) or subsequent versions.
The chronic value for multiple concentration_ tests will be determined using the geometric mean of the
highest concentration having no detectable impairment of reproduction or survival and the lowest
concentration that does have a detectable impairment of reproduction or survival, The definition of
"detectable impairment," collection methods, exposure regimes, and further statistical methods are
specified in the "North Carolina Phase II Chronic Whole Effluent Toxicity Test Procedure" (Revised -
February 1998) or subsequent versions.
All toxicity testing results required as part of this permit condition will be entered on the Effluent
Discharge Monitoring Form (MR-1) for the months in which tests were performed, using the
parameter code TGP313 for the pass/fail results and THP313 for the Chronic Value. Additionally, DWQ
Form AT-3 (original) is, to be sent to the following address:
Attention: North Carolina Division of Water Quality
Environmental Sciences Branch
1621 Mail Service Center
Raleigh, North Carolina 27699-1621
Completed Aquatic Toxicity Test Forms shall be filed with the Environmental Sciences Branch no
later than 30 days after the end of the reporting period for which the report is made.
Test data shall be complete, accurate, include all supporting chemical/physical measurements and
all concentration/response data, and be certified by laboratory supervisor and ORC or approved
designate signature. Total residual chlorine of the effluent toxicity sample must be measured and
reported if chlorine is employed for disinfection of the waste stream.
Should there be no discharge of flow from the facility during a month in which toxicity monitoring is
required, the permittee will complete the information located at the top of the aquatic toxicity (AT)
test form indicating the facility name, permit number, pipe number, county, and the month/year of
the report with the notation of "No Flow" in the comment area of the form. The report shall be
submitted to the Environmental Sciences Branch at the address cited above.
Should the permittee fail to monitor during a month in which toxicity monitoring is required,
monitoring will be required during the following month.
Should any test data from this monitoring requirement or tests performed by the North Carolina
Division of Water Quality indicate potential impacts to the receiving stream, this permit may be re-
opened and modified to include alternate monitoring requirements or limits.
NOTE: Failure to achieve test conditions as specified in the cited document, such as minimum
control organism survival, minimum control organism reproduction, and appropriate environmental
controls, shall constitute an invalid'test and will require immediate follow-up testing to be completed
no later than the last day of the month following the month of the initial monitoring.

Permit NC0004812
A.(4.) CHRONIC TOXICITY MONITORING/LIMIT — 1.0-MGD
The effluent discharge shall at no time exhibit observable inhibition of reproduction or significant
mortality to Ceriodaphnia dubia at an effluent concentration of 1.2%.
The permit holder shall perform at a minimum, auarteriu monitoring using test procedures outlined
in the "North Carolina Ceriodaphnia Chronic Effluent Bioassay Procedure," Revised February 1998,
or subsequent versions or "North Carolina Phase II Chronic Whole Effluent Toxicity Test Procedure"
(Revised -February 1998) or subsequent versions. The tests will be performed during the. months of
January, April, July and October. Effluent sampling for this testing'shall be performed at the
NPDES permitted final effluent discharge below all treatment processes.
If the test procedure performed as the first test of any single quarter results in a failure or ChV below
the permit limit, then multiple -concentration testing shall be performed at a minimum, in each of the
two following months as, described in "North Carolina Phase II Chronic Whole Effluent Toxicity Test
Procedure" (Revised -February 1998) or subsequent versions.
The chronic value for multiple concentration tests will be determined using the geometric mean of the
highest concentration having no detectable impairment of reproduction or survival and the lowest
concentration that does have a detectable impairment of reproduction or survival. The definition of
"detectable impairment," collection methods, exposure regimes, and further statistical methods are
specified in the "North Carolina Phase II Chronic Whole Effluent Toxicity Test Procedure" (Revised -
February 1998) or subsequent versions.
All toxicity, testing results required as part of this permit condition will be entered on the Effluent
Discharge Monitoring Form (MR-1) for the months in which tests were performed, using the
parameter code TGP3B for the pass/fail results and THP3B for the Chronic Value. Additionally, DWQ
Form AT-3 (original) is to be sent to the following address:
Attention:. North Carolina Division of Water Quality
Environmental Sciences Branch
1621 Mail Service Center
Raleigh, North Carolina 27699-1621
Completed Aquatic Toxicity Test Forms shall be filed with the Environmental Sciences Branch no
later than 30 days after the end of the reporting period for which the report is made.
Test data shall be complete, accurate, include all supporting chemical/physical measurements and
all concentration/response data, and be certified by laboratory supervisor and ORC or approved
designate signature. Total residual chlorine of the effluent toxicity sample must be measured and
reported if chlorine is employed for disinfection of the waste stream.
Should there be no discharge of flow from the facility during a month in which toxicity monitoring is
required, the permittee will complete the information located at the top of the aquatic toxicity (AT)
test form indicating the facility name, permit number, pipe number, county, and the month/year of
the report with the notation of "No Flow" in the comment area of the form. The report shall be
submitted to the Environmental Sciences Branch at the address cited above.
Should the permittee fail to monitor during a month in which toxicity monitoring is required,
monitoring will be required during the following month.
Should any test data from this monitoring requirement or tests performed by the North Carolina
Division of Water Quality indicate potential impacts to the receiving stream, this permit may be re-
opened and modified to include alternate monitoring requirements or limits.
NOTE: Failure to achieve test conditions as specified in the cited document, such as minimum
control organism survival, minimum control organism reproduction, and appropriate environmental
controls, shall constitute an invalid test and will require immediate follow-up testing to be completed
no later than the last day of the month following the month of the initial monitoring.

Permit NC0004812
A.(5.) TOTAL NITROGEN AND PHOSPHORUS MONITORING _'d
The Permittee shall calculate the annual mass loading of total nitrogen as the sum of
monthly loadings, according to the following equations:
(a) Monthly Mass Loading (lb/mo.) = TN/TP x Q x 8.34
where: TN = the average total nitrogen concentration (mg/L) of the
composite samples collected during the month at
the outfall
TP = The average total phosphorus concentration (mg/L) of
the composite samples collected during the month
at the outfall
Q . = the total wastewater flow discharged during the
month at -the outfall(MG/mo.)
8.34. = conversion factor, from (mg/L x MG) to pounds
(b) Annual Mass Loading (lb/yr). _ • (Monthly Mass Loadings) for the calendar year
The Permittee shall report the total nitrogen and total phosphorus concentration for
each sample and the monthly mass loading in the appropriate self -monitoring report
and the annual mass loading of total nitrogen and total phosphorus in the December
self -monitoring report for the year.
A (6). Color Permitting Requirements for Tier 1 Facility
This facility has been classified as a Tier 1 color discharger. The permittee will conduct
color monitoring of instream stations (upstream, downstream) on a monthly basis during
summer season (April -October). The permittee will record whether a color_ plume was
observed around the outfall..pipe during the monthly instream sampling events, and
include that information on the monthly discharge monitoring report. Effluent samples will
be collected monthly for color on a year-round basis. Color samples will be analyzed for
ADMI color at natural pH. Effluent samples will consist of 24-hour composites, while
instream samples will be collected as grabs. Samples will be analyzed by a state certified
laboratory.
If data, show that water quality .standards for color .are being violated by the discharge
permitted by the terms of this permit, then the Director may reopen this permit for the
purpose of imposing additional •requirements pursuant to 15A NCAC 2H.0114.
Alternatively, if future conditions change and color is no longer a component of the influent
wastestream, then the permittee may request a permit modification to remove color permit
requirements.

UNITED STATES ENVIRONMENTAL PROTECTION AGENCY
REGION 4
ATLANTA FEDERAL CENTER
61FORSYTH STREET
ATLANTA, GEORGIA 30303-8960
June 10, 2002
Mr. Dave Goodrich, Supervisor
NPDES Unit
Division of Water Quality
North Carolina Department of Environment and
Natural Resources
1617 Mail Service Center
Raleigh, NC 27699-1617
SUBJ: NPDES Permit Review
Pharr Yarns, Inc.
Permit No. NC0004812
1111M- uwe 0 W411
JUN 12 ]AL11yr
D
DEf;R - WATER
�_FORIT SOuor�
In accordance with the EPA/NCDENR MOA, we have completed our review of the draft
permit referenced above. EPA Region 4 has received a fax dated May 28, 2002, from you
relaying sampling data as requested in EPA's March 7, 2002, e-mail. EPA Region 4 has reviewed
this information and determined that no reasonable potential exists for an exceedence above an
existing water quality standard for the parameters tested and therefore no additional limits are
needed in the August 22, 2001, draft permit submitted to EPA for review.
We request that we be afforded an additional review opportunity only if significant
changes are made to the permit prior to issuance, or if additional significant comments to the
permit are received. Otherwise, please send us one copy of the final permit when issued. If you
have any questions, please feel free to contact me [phone] or at [e-mail] .
Sincerely, • L
Dee Stewart
Program Manager
Permits, Grants and Technical Assistance Branch
NPDES & Biosolids Section
Water Management Division
Internet Address (URL) • hV://www.spa.gov
RecyclaAlRecyclable •Printed wkh Vegetable ON Based Inks on Regded Paper (Mlnknum 3o%Podcone urter)

DENR/DWQ
ADDENDUM TO FACT SHEET FOR NPDES PERMIT DEVELOPMENT
NPDES No. NC0004812
Facility Information
Applicant/Facility Name:
Pharr Yarns, Inc.
Applicant Address:
100 Main Street, McAdenville, NC 28101
Facility Address:
147 Willow Drive, McAdenville, NC 28101
Permitted Flow
1.0 MGD
Type of Waste:
100% Industrial
Facility/Permit Status:
Class ItActive; Renewal
Count
Gaston Count
Miscellaneous
Receiving Stream:
South Fork
Catawba River
Regional Office:
MRO
Stream Classification:
VJ$=Hi 5 —
State Grid / USGS Quad:
F14SE/
303(d) Listed?
No
Permit Writer:
Natalie Sierra
Subbasin:
03-08-36
Date:
20Ma 2002
Drainage Area (mi2):
636
La[. 351 IS' 40" N
Long. 81004' 39" W
Summer 7Q10 (cfs)
125
Winter 7Q10 (cfs):
228
30Q2 (cfs)
310
Average Flow (cfs):
808
IWC (%):
1.2
BACKGROUND
The permit for Pharr Yarns went to public notice on August 27, 2001. It was held for
EPA comments, which were received on March 7, 2002. The following provides a response to
both the facility's comments and EPA's comments.
Application Data
Among EPA's comments was the objection that the full suite of testing required by EPA
Form 2C was not performed. The Division submitted a request to Pharr on April 12, 2002, for
the additional sampling requirements. The sample data were received on May 16, 2002. Of the
toxicants, cyanide, chromium, copper and zinc were detected. Chromium is already monitored
and limited in the current NPDES permit. Converting the allowable instream concentration of
chromium, 4082.3 ug/L, to pounds per day yields a limit of 33.9 lbs./day. This limit is less
stringent than that mandated by the federal effluent guidelines, so the technology -based limit will
remain in the permit. Copper, cyanide and zinc are present in levels well below the allowable
instream concentration as well as being at or below the ambient concentrations for these metals.
Reasonable potential
A reasonable potential analysis was performed for all detected parameters from Form 2C
(i.e. copper, cyanide and zinc) as well as chromium, for which DMR data were used. This
analysis showed no reasonable potential for copper, cyanide, chromium or zinc. Chromium will
continue to be limited in the permit because of the requirements stipulated by the federal effluent
guidelines for textile mills.
Fact Sheet
NPDES NC0004812 Renewal
Page I

COD limit
The COD limit in the draft permit was a limit that derived solely from the federal effluent
guidelines. In consideration of the fact that 73% of the waste at Pharr Yarns is domestic, the
Division feels that a BPJ limit for COD that takes this into consideration is appropriate. Facility
influent data suggests a 2.2 BOD/COD ratio. Using a daily max BOD limit of 45 mg/1- and a
monthly average BOD limit of 30 mg/L (as per the federal effluent guidelines for domestic
waste), correspondingly appropriate COD limits can be derived. By multiplying the BOD limits
by the permitted flow and the ratio of 2.2, monthly average poundage of COD of 401.8 (and a
daily max of 602.7) are derived. Multiplying these numbers by 7 3 % and adding them on to the
allocation from the process flow yields a monthly average COD limit of 590.3 lbs./day and a
daily maximum COD limit of 1430.7 lbs./day.
PROPOSED SCHEDULE FOR PERMIT ISSUANCE
Permit Scheduled to Issue:
NPDES DIVISION CONTACT
June 3, 2002
If you have questions regarding any of the above information or on the attached permit, please contact
Natalie Sierra at [phone] ext. 551.
NAME: DATE: 7/ 2
Fact Shoot
NPDES NCO004-812 Renewal
Pa-C 2

Re: pharr yams
u.
Subject: Re: pharr yarns
Date: Tue, 11 Jun 2002 07:52:09 -0400
From: [e-mail]
To: Natalie Sierra <[e-mail]>
Natalie,
I sent a no comment letter dated June 10 to North Carolina. You should
have it soon.
Dee
Natalie Sierra
<Natalie.Sierra@n To:
cmail.net> cc:
Subject:
06/10/02 03:40 PM
Dee Stewart/R4/USEPA/US@EPA
pharr yarns
Dee -
It is unclear to me as to whether or not I may issue Pharr Yarns. Do
you have any additional questions/issues with this permit?
Thanks,
Natalie
(See attached file: Natalie.Sierra.vcf)
Name: Natalie.Sierra.vcf
FJ Natalie. Sierra.vcf Type: Ward (texth-vcard)
Encoding: base64
1 of 1 6/12/02 11:07 AM

1617 MAIL SERVICE CENTER
RALEIGH, NC 27699-1617
NOTIFICATION OF INTENT
TO ISSUE A NPOES
TISMEP WASTEWATER PERMIT
Gastonia, NC
Gaston County
On the basis of thorough staff
review and application of NC
General Statute 143.21, Public
law 92-500 and other lawful
standards and regulations, the
North Carolina Environmental
Management Commission pro-
poses to issue a National Pollu-
tant Discharge Elimination Sys-
tem (NPDES) wastewater dis-
charge permit to the person(s)
listed below effective 45 days
from the publish dale of this no -
Lice.
Written comments regarding
I, SHEILA RANBURGER Legal Advertising Manager of the The Gaston Gaze)
the be ac-
cePted Prop
ntiil30 days apermitlferr the
do certify that the advertisement of NCDENR
publish date of this notice. All
comments received prior to that
Entitle NPDES
date are considered in the final
determinations regarding the
Proposed permit. The Director
of the NC Division of Water
Quality may decide to hold a
public meeting for the proposed
permit should the Division ro-
Measuring 11.75 Inches appeared in The Gaston Gazette, a newspaper published
ceive a significant degree of
Public interest.
Gaston County, Gastonia, NC, in issues
Copies of the draft permit and
other supporting information on
its used to determine comk-
tions present in the draft permit
are available upon request and
payment of the costs of repro-
duction. Mail comments and/or
requests for information to the
NC Division of Water Quality at
the above address or call Ms.
Christie Jackson at
AUGUST 27, 2001
[phone] extension 538,
Please include the NPDES per-
mit number (ahached) in any
communication. Interested per-
sons may also visit the Division
of Water Quality at 512 N.
Salisbury Street, Raleigh, NC
27604-1148 between the tours
of 8:00 a.m. and 5:00 p.m. to
review information on file.
NPDES Permit number
SHEILARANBURGER N C D o e 4 6 3 8
Legal Advertising Mana; Fur° t H;n°P mN o �,,�
2T707 has applied for a facility
located in Gaston County
Sworn to and subscribed before me this da of ,20C dschrging was ewater into UT
y Crowders Creek in the Cataw-
ba River Basin. Currently are
water quality limited. This dis-
charge may affect future alloca-
tions in this portion of the re-
f ceiving stream.
My commission expires May 25, 2003
Notary Public NPDES Permit Number
NC0004812, Pharr Yams In-
dAbW WWTP, PO Box 1939,
McAdemrille, NC 28101 has ap-
plied for a permit renewal br a
facility located in Gaston Coup
ty discharging treated
wastewater into South Fork Ca-
tawba River in the Catawba
River Basin. Currently Coll -
form, total nitrogen, and total
Phosphorus are water quality
limited. This discharge may af-
fect future allocations in this
Portion of the receiving stream.
NPDES Permit Number
NCD072061, Heater Utilities,
Inc. (Far Run. WTP), PO Box
4889, Cary, NC 27519 has ap-
plied for a permit renewal for a
faiility located in Gaston County
discharging filter -backwash
wastewater into an unnamed
tributary to Crowders Creek in
the Catawba River Basin. Cur-
rently no parameters are water
quality limited. This diccharga
may affect future allocations in
this Ponion of he rope.,..__

Pharr -Palomar
Pharr International, Inc.
Sylvania Yorn Systems, Inc.
PHARR
YARNS
Pharr Yarns, Im.
P.O. Box1939
100 Main Street
McAdenville, N( 28101-1939
Telephone: [phone]
Facsimile: 704/824-0072
December 10, 2001
Ms. Natalie Sierra
NC DENR-DWQ-NPDES Unit
1617 Mail Service Center
Raleigh, NC 27699-1617
Subject: COD Limitation Study, Pharr Yarns, WWTP NPDES
Permit Renewal Permit No. NC0004812, Gaston Co.
Dear Ms. Sierra:
N'
r7
O
C>
The effluent COD limitation in the draft of our permit has been reduced
from an average 1607 Ibs/day to 188.5 lbs./day or 88% and the maximum
of 4145 Ibs./day to 828 Ibs/day which is a reduction of 80%. None of the
other parameters have been reduced as much as the COD. However, our
present average effluent COD of 220 mg/I would not be in compliance with
an average flow above .103 mgd even though we achieve 86% average
removal.
We appreciate your assistance in explaining the permitting strategy
described on page two of the renewal and understand that the ratio of
industrial to domestic wastewater determines the COD concentration
limits. Based on normal domestic wastewater and the production of the
Space Dye industrial facility the COD influent concentration would be
expected to be low enough to achieve the proposed limits. A study of COD
sources in the influent has been completed and shows that there is a high
concentration of COD in the domestic wastewater.
Please find attached the subject analysis for your review. The composite
samples were collected from combined influent domestic wastewater from
our Complex 46, Plant No. 23, and 185 plant facilities. The average ratio
of COD/BOD-5 of 2.2:1 is higher than normal domestic wastewater due to
a carpet manufacturing process where wastewater is collected and
discharged from the heat setting process as follows:
Our Complex 46 and 185 facilities manufacture nylon and polyester yarns
for the carpet industry. The initial production process is conducted at

Page 2
Complex 46 where a liquid yarn finish is applied to the yarn fiber prior to
spinning.
The yarn finish is a blend of biodegradable fatty esters, non-ionic, and
anionic surfactants that are applied by spraying it on the fiber with
chemical pumps. Wastewater from cleaning. of the chemical day tanks
drains to the sewer collection system. This is a small amount per day
containing a high COD. After the yarn is spun, it enters a heat set
operation where low pressure steam comes into contact with the yarn to
set the yam so that it will have a memory or retain its shape and
consistency. The volatile solids are released with the steam via stack to
the atmosphere as air emissions which are included in our air emissions
permit no. 04364R09. The steam condensate containing some of the _yarn
finish is transferred by vacuum pump to a 2,000 gallon storage/disposal
tank located at the Complex 46 and 185 .plants. Wastewater from a
cleaning process integral of the heat set machine is also collected in the
storage/disposal tank. This process involves the cleaning of screens used
inside the machine that conveys yarn. The screens are dipped into a 200
gallon .tank containing a 2% solution of cleaning compound in 200 gallons
of water. The cleaning compound contains 30% potassium hydroxide
solution. A sample collected from the storage tank had a COD of 23,500
mg/L. Approximately 2000 gallons per week is dripped from the storage
tanks into the sewer collection system.
Samples were collected of influent from Space Dye (industrial), the
wastewater plant digester supernatant, and the yarn finish
storage/disposal tank for BOD-5 and COD analysis as follows:
COD mg/L BOD-5 mA/L Ratio
Space Dye
2,850
325
8.7:1
Digester
2,500
149
16.8:1
Yarn Finish
23,500
5,417
4.3:1
Also the combined influent to the WWTP and effluent were analyzed for
COD and BOD-5 for percent removal during the activated sludge
treatment process as follows:
Influent Effluent % Removal
COD 1600 mg/L 200 mg/L 86%
BOD 370 mg/L 4 mg/L 99%

Page 3
The plant process yields excellent removal of COD, however as previously
stated the permit monthly average of 188.5 lbs. / day is exceeded with the
average 220 mg/L at a flow of over .103 mgd. All other proposed
parameters except the COD and total nitrogen can be achieved with the
present wwtp process.
Also, please consider the following for allocating the percent of flow from
our Space Dye facility. The Space Dye wastewater flow rate is
proportional to the production of dyed yam while the wastewater flow from
the Complex 46, Plant 23, and 185 spinning mills is determined by
domestic wastewater from the rest rooms plus the amount of continuous
bleed from the boilers and air conditioning equipment. The maximum
amount of "domestic" wastewater flow based on the size of the air
conditioning and steam production equipment plus the maximum number
of employees is as follows:
Air Washers 18,700 gpd
Cooling Towers 26,350 gpd
Boilers 7,500 gpd
Rest Rooms (1200 employees @ 25 gal./ employee) 30,000 gpd
Total
82,550 gpd
Based on the maximum daily domestic wastewater flow of 82,550 and the
permitted maximum daily flow of 500,000 gpd, we would like to retain the
417,450 gpd for industrial wastewater from our Space Dye facility. This
would amount to 83% industrial and 17% domestic wastewater.
Thank you for your assistance. Please contact me at [phone] for
any other information needed.
Sincerely,
Mike Church
Environmental Engineer
Attachments: Wastewater Analysis and MSDS

DATE
DOM. COD m /I
DOM. BOD m /L
OTHER RESULTS
Space Dye COD: 2850
Comb. Inf. COD: 1600
Yarn Finish COD: 23500
Digester COD: 2500
Space Dye BOD: 325
Comb. Inf. BOD: 370
Yarn Finish BOD: 5417
11/6/01
180
154
Digester BOD: 149
11/7/01
210
154
11/8/01
310
134
11/9/01
385
139
11/12/011
345
145
11 /13/01
325
129
11/14/01
338
134
11 /15/01
250
154
x
11 /16/01
360
145
11 /19/01
350
158
11 /20/01
380
160
11/21/01
360
134

r
Aateria! Safety Data Sheet U.S. Department of Labor
lay ". uJed to comply with Occupational Safety and Health Administration
)SHA's Hazard Communication Standard, (Non -Mandatory Form)
9 CFR 1310.1200. Standard must be Form Approved f' �Itail
onsulted•for specific requirements. OMB No. 1218-0072
LatQ Note: Blank spaces are not permitted. If any item is not applicable, or no
]F1rTITY (As Used
_. information is avmW*, the specs must be marked to indicate that.
;ection
ianufacturer'S Name Emergency Telephone Number
Pro Chemical Products Inc. 615-265-4966 or 5055
ddress (Number. Soria(, City, State, and LP Coda) Telephone Number for Information
702 E. 13th. Street 615-265-4966 or 5055
Tennessee 37408
88
of Preparer
section II — Hazardous Ingredients/identity Information
Other Limits
lazardous Components (Specific Chemical Identity, Common Name(s)) OSHA PEL ACGIH TLV Recommended % (optional)
Potassium Hydroxide KOH CAS A 131,9- 8-
r
ection III — Physical/Chemical Characteristics
hums•
_-
Rucnym
PERSONAE
PROTECTION
Mc,mi nie, nu
cling Pant Specific Gravity (H20 - 1) 1.15
212
Matting Point
apor Pressure (mmHg.) to
apor Density (AIR 1) Evaporation Rate NA
(Butyl Acetate - 1)
olubility in water Corl-pletely -
ppearance and Odor
Clear liquid with slight surfactant odor
,ection IV — Fire and Explosion Hazard Data
Lash Point (Method Used) f-laminable Limier LEL UEL
Non rlarrmable
xunguishing Media
PTA
ecial Fire Fighting Procedures
_/ Avoid contact with skin and eves - wear self contained breathing annara=
and full protective cloth* .
Inusual Fire and Explosion Hazards D — — O
None
OSHA 174. Seol. 19a5

Section V - Reactivity Data
Stability
Unstable
Conditions to Avoid _
I
Stable
X
Incompatibility (Materials to Avoid)
Ac
Tin.
Hazardous Decomposition or Byproducts
e• ,+� _ o— 4z— -., A },v rc%arti r7rt Wlt�1 TfT1i11L1n1-
H dr en
High
r
Hazardous '
May Occur
Conditions to Avoid
Polymerization
Will Not Occur
X
co.•4inn Vt _ Health Hazard Data
�oute(s) of ntry:
Inhalation? Skin? in osrion r
Derma- contact is the Primary route of occupational a osure. Use with caution.
Health Hazards (Acute and Chronic)
Diluted solutions can cause burns on prolonged contact. Does not always cause an immediate
burning sensation. If suspected contact, wash skin irm--adiately and neutralize with
vinegar. Superficial skin destructign possible. OSHA Regwated?
Carcinogenicity: NTP? [ARC Monographs?
Signs and Symptoms of Ex ure
SKIN: Drying or burning sensation. High irritation
EYES: Burning sensation -can cloud vision. Can cause eve and skin da>rtacre.
Medical Conditions
Generally Aggravated by Exposure None Knowri
Emer envy and First Aid Procedures
FYS SKIN: Flush with large amounts of water .for 15 minutes - Remove contairinated clot_ in
and shoes, Call a Physician. Can Neutralize with "VINEGAR" INGESTIQN • T?ri nk 1 araP armI m t
Section VII — Precautions for Safe Handling anc Use of water- Seek medical at . tention for all accide
Steps to Be Taken in Case Material Is Released or Spilled
LARGE SPILLS: Neutralize and contact local authorities on disposal. .
Waste Disposai Method
Dispose of in accordance with all applicable Federal State and Local regulations.
Surfactants are biodegradable.
Precautions to Be Taken in Handling and Storing nhser ize nreranit-nrtc
no net -freeze SinrP P ---- ^^*^�., i.i•,em� rat YP
Other Precautions
The information here is believed to be accurate not warranted. Recipients are advise to
confirm if information is current applicable and suitable to their circumstances.
Section VIII — Control Measures
Respiratory Protection (Specify Type)
Ventilation Local Exhaust Preferred
Mechanical (Gerre )
Gloves
Other Protective
T=ervi.ous g.
othing or Equipment
Special
Other
(Rubber or vinyl) Eye Protection Chemical splash goP,Fles .
ve
if bodv contact
Work/Hygienic Practices
P*" 2 o USOPO 19e6-491-5'9/45775

Comments: Pharr Mills - NC 0004812
Subject: Comments: Pharr Mills - NC 0004812
Date: Thu, 07 Mar 2002 09:40:05 -0500
From: [e-mail]
To: [e-mail]
CC: [e-mail], [e-mail], [e-mail],
[e-mail], [e-mail],
[e-mail]
Comments on Pharr Mills, NC0004812. I would be glad to talk to you
about any of the comments below; but wanted to provide our initial
reactions. Thank you for providing the requested information and any
clarifications as needed.
Dee Stewart
EPA R4
404/562-9334
1) The application used for Pharr Yarns is the NC Industrial
application, which is not significantly the same as EPA Form 2C. EPA
Form 2C is appropriate for Pharr Yarns since this facility is a textile
industry and hence considered a primary industry. Volatile, acid, and
base/neutral GC/MS fractions (per 40 CFR 122, Appendix D and 40
CFR122.21(g)(7)(v)(A)) samples were submitted in an analysis report
dated 3/29/01 and should be evaluated for reasonable potential for
appropriate permit limits. Additionally, EPA Form 2C requires a
sample for all total metals, cyanide, and total phenols, per 40 CFR
122.21(g)(7)(v)(B). The only metal submitted was for total chromium.
Samples for all total metals listed in Table III, 40 CFR 122, Appendix D
should be collected and evaluated for reasonable potential for
appropriate limits. EPA Form 2C also requires BOD5, COD, TOC, TSS,
NH3, temp (both winter and summer), and pH, per 40 CFR
122.21(g)(7)(iii). The application included COD, and TN information,
but no data was included for BOD5, TOC, TSS, temperature, and pH. Also,
the permittee must address the requirements of conventional and
nonconventional pollutants at 40 CFR 122.21(g)(7)(vi)(A). Insufficient
application information would be basis for an EPA objection per 40 CFR
122.21(e)(1).
EPA would accept a condition in the draft permit to require monitoring
and submital of missing EPA Form 2C information to NC within the first 6
months of permit issuance. The permit should also include a specific
reopener if the results indicate the need for permit modification.
2) The fact sheet states that no reasonable potential was performed for
permit renewal because no toxicants are monitored under the current
permit. EPA requests that a reasonable potential analysis, in
accordance with 40 CFR122.44(d), be performed for each pollutant when
all data is collected, per the requirements of EPA Form 2C, and in
accordance with North Carolina's Reasonable Potential Procedures.
3) 40 CFR 122.45(b)(2)(i) states that production values should be based
upon a reasonable measure of actual production. The facility listed
production as 66,277 pounds per week and a daily maximum of 36,248
pounds. The current average effluent flow at the facility is listed as
0.076 MGD. 40 CFR 122.45(b)(2)(ii)(A)(1) does allow for the
development of alternate permit limitations based upon anticipated
increased production levels. Anticipated production levels are not
documented in the permit application. Appendix A referenced in'the fact
sheet is missing from the application package and EPA is unsure what
1 of 2 3/7/02 10:21 AM

Comment: Pharr Mills - NC 0004812
production values were used to develop technology based limits for a 0.5
and 1.0 MGD discharge and requests clarification. Inappropriate
production values would be a basis for an EPA objection per 40 CFR
122.45 (b) (2) (i) .
2 of 2 3/7/02 10:21 AM

Pharr -Palomar Pharr Yarns, Inc.
Phan International, Inc P.O. Box 1939
Sylvania Yarn Systems, Inc. 100 Main Street
McAdenville, K 28101-1939
telephone: [phone]
Facsimile: 704/824-0072
September 5, 2001
Ms. Natalie Sierra
NCDENR-DWQ-NPDES Unit
1617 Mail Service Center
Raleigh NC 27699-1617
P H AR R Re: Pharr Yarns, Inc. wwTP
Y A R N S Permit No. NC0004812
Dear Ms. Sierra,
Pharr Yams would like to request a change in wording in paragraph 1 on the
Supplement to Permit Cover Sheet. We would like it to read as follows:
Pharr Yams, Inc. is hereby authorized to:
1 0
� N
>:
w
xI
CID
�
oa
t
Continue to operate an existing 1.0 MGD wastewater treatment facility for the
treatment of industrial and domestic wastewater consisting of an aeration basin
two clarifiers with alum and polymer addition, mixed media pressure filters,
an aerobic digester, sludge thickening, dewatering belt press, and chlorine
disinfection located at Pharr Yams Wastewater Treatment Plant, 147 Willow Drive
McAdenville NC in Gaston County.
We are asking for this change due to the fact that we now only run 1 aeration basin
and the other is being used as an aerobic digester.
Thank you in advance for attention to this detail.
If you have any questions please feel free to contact me at [phone].
Mike Church
Environmental Engineer
Pharr Yams, Inc.

State of North Carolina
Department of Environment
and Natural Resources
Division of Water Quality
Michael F. Easley, Governor
William G. Ross, Jr., Secretary
Kerr T. Stevens, Director
August 22, 2001
A1T
NCDENR
NORTH CAROLINA DEPARTMENT OF
ENVIRONMENT AND NATURAL RESOURCES
MEMORANDUM RECEIVED -
WATFR title! 1Ty cF(:Tlor wJ d 2 7 2001
To: Britt Setzer AUG 3
NC DENR / DEH / Regional Engineer
Mooresville Regional Office'
Non-Dischar9ePennittir>4�
From: Natalie Sierra
NPDES Unit
Subject: Review of Draft NPDES Permit NC0004812
Pharr Yarns WWTP
—
i
Gaston County
c�
Please indicate below your agency's position or viewpoint on the draft permit and return this fo
ept tuber
W
2001. If you have any questions on the draft permit, please contact me at the telephone number
r e- ail a
a
listed at the bottom of this page.
—'dress
3
n
w
WO
Od
SE: (Check one)oncur
with the issuance of this permit provided the facility is operated and maintained properly,
WC
the stated effluent limits
e met prior to discharge, and the discharge does not contravene the designated water quality standards.
❑ Concurs with issuance of the above permit, provided the following conditions are met:
❑ Opposes the issuance of the above permit, based on reasons stated below, or attached:
1617 Mail Service Center, Raleigh, North Carolina 27699-1617 919 733.5083, extension 511 (tax) 919 733-0719
Vlsrrus oNTRE INTERNET @ httpWh2o.enr.state.nc.us/NPDES Charles.Weaver® ncmail.net

TEXTILE EFFLUENT LIMITS SPREADSHEET
PERMIT NO: NC0004812
PERMITTEE: PHARR YARNS, INC.
COUNTY: GASTON
PERMITTED FLOW: 1 MGD
PRODUCTION DATA (in Ibs/dav):
AVERAGE MAXIMUM
FLOW
0.076
DAILY PRODUCTION
13255 36248
1
WEEKLY PRODUCTION
9468 16504
FROM 40CFR 410.70 SUBPART G (all limits in Ibs/1000 Ibs)
POLLUTANT
DAILY MAX
MONTHLY AVERAGE,-
BOD5
6.8
3.4
COD
84.6
42.3
TSS
17.4
8.7
Sulfide
0.24
0.12
Phenol
0.12
0.06
Total Chromium
0.12
0.06
pH
must be between 6 and 9 at all times
LIMITS
POLLUTANT
DAILY MAX
MONTHLY AVERAGE
BOD5
246.5
56.1
COD
3066.6
698.1
TSS
630.7
143.6
Sulfide
8.7
2.0
Phenol
4.3
1.0
Total Chromium
4.3
1.0
pH
must be between 6 and 9 at all times
FOR PHARR YARNS, ONLY 27% OF FLOW IS
PROCESS FLOW ADJUST LIMITS ACCORDINGLY:
POLLUTANT
DAILY MAX
MONTHLY AVERAGE
BOD5
66.6
15.2
COD
828.0
188.5
TSS
170.3
38.8
Sulfide
2.3
0.5
Phenol
1.2
0.3
Total Chromium
1.2
0.3
pH
must be between 6 and 9 at all times
FINAL LIMITS
BASED ON 40CFR410.70 SUBPART G
STOCK AND YARN FINISHING SUBCATEGORY
DOMESTIC WASTE IS 73%,
ADD ALLOCATION FOR THAT
OS SUTANT (DAILY ZAX OI MONTHLY AVERAGE
182.6
l
i
340.5
197.8
' original BOD limits were 390 lb/day (monthly ave)
828.0
188.5
and 780 lb/day (daily max), so these limits are still
444.3
221.4
protective of DO
e
2.3
0.5
al
1.2
0.3
Chromium
1.2
0.3

TEXTILE EFFLUENT LIMITS SPREADSHEET
PERMIT NO:
NC0004812
PERMITTEE:
PHARR YARNS, INC.
COUNTY:
GASTON
PERMITTED FLOW:
0.5 MGD
PRODUCTION DATA:
AVERAGE MAXIMUM
FLOW
0.076
DAILY PRODUCTION
13255 36248
MONTHLY AVG.
9468 16504
FROM 40CFR 410.70 SUBPART G
(all limits in Ibs/1000 IIts)
POLLUTANT
DAILY MAX
MONTHLY AVERAGE
SODS
6.8
3.4
COD
84.6
42.3
TSS
17.4
8.7
Sulfide
0.24
0.12
Phenol
0.12
0.06
Total Chromium
0.12
0.06
PH
must be between 6 and 9 at all times
LIMITS
POLLUTANT
DAILY MAX..
MONTHLY AVERAGE
BOOS
246.5
56.1
COD
3066.6
698.1
TSS
630.7
143.6
Sulfide
8.7
2.0
Phenol
4.3
1.0
Total Chromium
4.3
1.0
PH
must be between 6 and 9 at all times
FOR PHARR YARNS, ONLY 27% OF FLOW IS
PROCESS FLOW ADJUST LIMITS ACCORDINGLY:
POLLUTANT
DAILY MAX
MONTHLY AVERAGE
BODS
66.6
15.2
COD
828.0
188.5
TSS
170.3
38.8
Sulfide
2.3
0.5
Phenol
1.2
0.3
Total Chromium
1.2
0.3
PH
must be between 6 and 9 at all times
FINAL LIMITS
POLLUTANT
DAILY MAX
MONTHLY AVERAGE r(
BOD5
203.5
106.5
COD
828.0
188.'.
TSS
307.3
130.1
Sulfide
2.3
0.°
Phenol
1.2
0.3
Total Chromium
1.2
0.3
BASED ON 40CFR410.70 SUBPART G
STOCK AND YARN FINISHING SUBCATEGORY
DOMESTIC WASTE IS 73%,
ADD ALLOCATION FOR THAT
OD UTANT IDAILYIM OI MONTHLY AVERAGE1
TSS
original BOO limits were 390 lb/day (monthly ave)
nd 780 lb/day (daily max), so these limits are still
rotective of DO

NC0004812 Pharr Yarns WWTP
Gaston County
Instream Data Review
UPSTREAM DOWNSTREAM
Date
Temperature
(Celcius)
Dissolved Oxygen Fecal Coliform
(mg/1) (#/100ml)
Conductivity
(umhos/cm)
Date
Temperature
(Celcius)
Dissolved ffecal Coliform
(mg/1) (#/100ml)
Conductivity
(umhos/cm)
Jan-99
5.5
11.63
9.1
126
Jan-99
5.5
11.68
2.9
125.5
Feb-99
7.25
11.48
2.11
103
Feb-99
7.25
11.53
1.9
103
Mar-99
8
10.56
3.8
113
Mar-99
8
10.6
1.1
113.8
Apr-99
16
8.7
22
130
Apr-99
16
8.8
29
130
May-99
17.25
8.33
11.9
127
May-99
17.25
8.43
9.4
127.3
Jun-99
21
6.35
14
189
Jun-99
21
6.41
15
189
Jul-99
23.69
6.35
78
232
Jul-99
23.69
6.35
50
232
Aug-99
25.69
5.8
119
371
Aug-99
25.69
5.8
145
371
Sep-99
23
6.74
116
342
Sep-99
23
6.74
103
342
Oct-99
16.5
10.13
237
232
Oct-99
16.25
10.13
207
232
Nov-99
13.2
7.8
94.5
246
Nov-99
13.2
7.8
89.9
246
Dec-99
9
7.2
166
176
Dec-99
9
7.2
230
175
Jan-00
8.3
8.8
153
120
Jan-00
8.3
8.8
150
120
Feb-00
7.6
9.38
1.03
130
Feb-00
7.6
9.38
1.08
130
Mar-00
12
8.58
15
173
Mar-00
12
8.58
18
173
Apr-00
14.5
8.6
58
151
Apr-00
14.5
8.6
68
151
Jun-00
24
6.1
6.4
287
Jun-00
24
6.1
9.4
287
Jul-00
24.5
5.5
35
233
Jul-00
24.5
5.5
40
233
Aug-00
23.73
5.62
8.5
291
Aug-00
23.73
5.62
16
291
Sep-00
20.33
6.41
11.2
232
Sep-00
20.33
6.41
8.5
232
Oct-00
14
7.34
<2
245
Oct-00
14
7.34
1.38
245
Nov-00
10.5
8.73
<2
231
Nov-00
15
8.73
1.3
231
Dec-00
5.7
10.8
2
197
Dec-00
5.7
10.8
2
197
Jan-01
4.2
12.5
1.2
170
Jan-01
4.2
12.5
1.7
170
Feb-01
7.8
11
<2
131
Feb-01
7.8
11
1.6
131
Mar-01
10
10.3
<2
127
Mar-01
10
10.3
<2
127
Average
14.36
8.49
52.94
196.35
14.52
8.51
48.13
196.33
Max
25.69
12.5
237
371
25.69
12.5
230
371
Min
4.2
5.5
1.03
103
4.2
5.5
1.08
103

r.
T
30
25
20
10
5
0 -I—
Sep-98
Jan-99 Apr-99 Jul-99 Oct-99 Feb-00
Date
May-00 Aug-00 Dec-00 Mar-01 Jun-01
�- Upstream
Temperature
--� Downstream
Temperature

r•
14
12
10
W
E
c 8
m
tM
X
O
V
0
0
6
N
N
0
4
2
0!
Sep-98 Jan-99 Apr-99
Jul-99 Oct-99 Feb-00 May-00 Aug-00 Dec-00 Mar-01 Jun-01
Date
-�- Upstream D.O.
- Downstream D.O.

r.
HOO
350
9
E 250
N
O
r
E
3
200
w
a
0 150
�s
100
50
0 --
Sep-98
Jan-99 Apr-99 Jul-99 Oct-99 Feb-00
Date
May-00 Aug-00 Dec-00 Mar-01 Jun-01
- Upstream
—� Downstream

r• -
250
200
150
E
0
0
T
v
E 100
L
w
0
U
50
Sei
-50
- K
-98 Jan-99 Apr-99 Jul-99 Oct-99 Feb-00 May-00 Aug-00 Dec-00 Mar-01 Ju
Date
—0 Upstream
—ra-- Downstream
-01

Whole Effluent Toxicity Testing Self -Monitoring Summary April 19. 2001"
FACILITY REQUIREMENT
YEAR JAN
PER
MAR APR
MAY IfIN
IfIL
AUG SEP
CUT
NOV DEC
PeOusewed HOD"" Chin Penn clue lion: 31%(Grab)
107 —
Pe
— —
FO9 Fail
Pau
Pass —
—
Pass —
NC0046809/001 Begim LIAM Fas sa y: QP/F + Feb May Aug Nov NonCunp:Smgle
19Po —
Pr
— —
NRIF.0 Pill
—
Pass —
—
Pass —
Comry: Guill Region: WSRO Subbasin: CPF01
1999 —
Pra
— —
POr —
—
Pass --
-
Pam —
PF:0.02 Spw:isl
2000 _
Pon
— —
Pm —
—
Pal _.
_.
Pm —
7QI0:OX IWC(%)30.6 ceder
2Wl —
Pll
Perdr lot. Lewlalon Pwmchrlhn:0A1%
Y 107 +W
—
— x90
— —
tan
at �90—
NC0028835/001 BegiteWU 99g Fregall QP/F + Jan Apr JWOct + NonCanp:SinWe
1996 s90
—
— e90
— —
25.2
— --
Pass
— —
County: Berne Region: WARD Suhbain: ROADS
Due Puce
—
— Pam
— —
Pam
— --
Late
Pau —
PF:3.0 Sal
2000 Pon
—
— Pm
— —
Pas
-- --
Pass
— —
7QIO:1102 IWC(%)e.42 Doer:
"I Pons
—
Pill Yarn, lue. Palmist 11%
1991 P. —
— Pus —
— Pass —
-- Fail.Pass -- -
N000041112A101 Be&VI/1991 Frail QP/F + Jr Apr Jul Oct + NonCeser lgle
1999 Pam —
— Pal —
— Pass --
-- Pase -- —
County: Geawn Region: MRO Subbases: CTB36
1999 Pus _.
_ Ivu —
— Pam —
— Pass
PF: 1.0 Special
2000 pat —
— Pr —
— Paul --
— Pass — —
7QIO:125D AWC(%xI= Uden
2W1 Pet —
PYWiln Petroleum Perm 24hr per. lion: 9054
IN? N
—
—
H
Pe
—
N".
—
—
Pass
N(D084690/0(lI Begin:5/1/2000 Frequency: Q PIE + Ion Apr JWOcI + NonCmnP:Sinefe
1995 NRm
H
H
H
H
ti
Pan.Pua
Pal
Pte.pass
Pass
—
—
County: EEJg aylse Region: RRO Stbbaain: TAR02
1999 Peon
—
—
P®
—
—
Pre
—
—
Late
L4O
tan
PF: 0.M32 Spcciu
20W Lan
H
H
Pan
—
H
lava
Fall
Pass
Pass
—
H
0Q10: 36A IWC(%)A.18 Urdu
=I Pat
—
PYWIpaPlpeLineCo. PERM: 24M LCSO AC MOW ENS FTRD(GRAB)
1BW —
—
—
—
—
—
—
—
--
—
—
—
NC0032875/002 Begirt:7/l/1994 Ftequeltcy: 50WD/A NoaCtmp:
1999 —
—
—
—
—
—
—
—
—
—
—
NRAI
County: lohtnton Region: RRO Subbsan: NEU02
1999 —
—
—
H
H
N
H
H
—
H
H
H
PF: VAR Specivt
MOu H
H
H
H
H
H
H
—
—
H
H
H
7Q10: 0.0 IWC(%):90 Ordal
2Wi H
H
H
Plimps Pipeline Ca. Perm 24hr ec monit Wia Bhd(gtab)
IN? —
—
—
—
—
—
—
—
—
—
—
—
NCtl032899001 BegimB/1/1999 Presust 5OWD/A NonCamp:
I89a —
—
—
—
—
—
—
—
—
—
—
21.71.10.4
County: Johrnte. Region: RRO Subbasiv: NEU02
1999 —
—
H
H
H
H
H
H
.IW2g
H
H
H
PF: N/A 'pal
all H
SL2
H
H
H
H
H
—
—
H
H
H
TQm.. 0.0 IWC(%):IW.O tlohc
M1 H
N
H
Ph Nips Plpellne Co. W I Perm 24hr LC50 u ale as Md (gab)
two NR,tIW
—
—
—
—
—
—
—
—
—
—
—
NCM1328911001 Begin:9/1/19% FreseiA NonComp:
199a e100
—
—
—
—
—
—
—
—
—
—
—
Comty MaeuenLug Regim MRO Subbuin: CfB34
INN 20.2
——
PF: VAR sill
2000-
7QW:0.0 IWC(%):IW Ord-
M1 739
—
PhiWpa Plpellae CO. ND Penn 24hr LC50 r nal Wis Md (gab)
19W NR"'W
——
NC0032891/002 Begi¢9/1/1996 Feaqumry:A NonComp:
19911 s100
--
--
—
—
—
—
—
—
—
—
—
County: Mecuenbng Regan: MRO Subbain: CfB34
1999 >100
--
—
—
—
—
—
—
—
—
—
—
PF: VAR Sped
20W-
1Q10:0.0 IWC(%):IW Order:
2001 NA
—
Phillips Maidng Cal Pennularmpflim:wA
Y DIN —
—
Pass
Pas
—
Pass
Pam
NC0001881/Al Begin:9/12000 Fabunq:Q + Madura Sep Dec * NonCmnp:Sink,
19011 —
—
Pass
—
—
pees
—
—
Pus
--
--
Pass
Colty Craven Region: WARO Sobbua: Ell
1889 —
--
Pass
—
—
Fees
--
—
Pass
—
—
Pas
PF: 0.10 Sill
2W] —
—
Pass
—
—
Pass
—
—
Fail
Pass
—
P.
TQIO: MAU IWC(%):100 Oedee:
2W1
Pass
Pkt Dye Acquitldou Clra.-001 Parm 24hr u 1Jflim: 9U°A
1992 —
Pon
—
—
Pra
_
_
pus
—
—
Pass
_
NC0003M7/001 Begin:41/1998 Frcqumry:Q + Feb May Aug Nav + NonConel tingle
1999 —
Pw
—
—
Pala,
-
—
Fal
Fall
a1W
Pass
—
Coal C1rwon Region: WARD Subbao: CH003
1999 Paul
NR
NR
Pra
Pra
Pam
Pass
PF: 1.5 sped
2Wd —
Pal
—
—
Pone
—
—
pas
—
—
NR
Pau
7Q10: TWAL IWC(%)NA 0.der
=I Pon
Pr
Nbl MOounia WWTP Perel iim: 3%; ifpf3DMGD chr lion 5%
P1992 Pal
—
—
Peso
—
—
Fail
Pon
—
Pau
--
—
NC002664dW1 Bepn:3/1/1"ll Fasoba :QP/F + Jr Apr JWOct + Noi,ConP:Single
im Paul
—
—
IJIa
NR
NR
Pre
—
—
NW —
—
—
County;
Counry: Suary Region: WSRO Subbaan: YAD03
1999 NWPat
—
—
Par
—
—
Pre
—
—
Pau
--
-
PF: 1.5 Sped
21100 pre
—
—
Pra
—
—
Pm
—
—
Fors
—
—
9QIB.82.2 iWC(Ol ord.r:
2001 Pass
—
LEGEND:
PERM=Permit Requirement LEf-Administtanve LeiterTarget Folquetwy- Monitoring fraluers, Q-Quarterly M-M.My; BM-Butua ;SA -Semiannually; A -Annually; Ol Only when iixhargm8; 0. Discontinued neonenng rWWremmt
Begin=First monN requited yQ1U=Rcxiving svmm low Bow carrion (cfa) +=quarterly rlmWueing increases to ttwnWyupon fN'Iwe or NR M.N Nutt ngmu mcn-ex.Jm,Apr,JW,Oct NuOCamp= Cul Canplial Ralu'aement
PF=PcnruteJBow(MGD) IWCA=Imuaunawawcoacentntion P/F=Pas.4Fail tat AC=Acura CHR=Cal
DOME ..... f- Fathead Mitaww: e - CetiWapMia cep.; any - Mysid shosel ChV - Chronic value; P - Mortality of al peoPantsge at hil canembation; at- Petfomad by DWQ Aquatic Tox Unt, bt- Bad all
Reporting Notation '.--= Data tnlrequimb NR-Not reported Fuiliry Activity Snlr:I-Inactive,N-Newly lmueJ(To onrm4uN); H-Active bon Wtdiscbargin&?-Moon data available for rnonNmgttwion;•=ORC eigrlue needed
36

1 CJ�I tT T L 'FUKTex l z -FAc -"
��-t rt-I�uc.�i oral
—cdwz
I vl-El
-02c v' d 'L ►.l
_ Sv's-l-m
—►N IT -m
L' t1to2 ipt,
NCOOO>-aj Z
�qtmp- YES
Rc�wIAL
- K1 i721-r'p-
OCT- T
2 oT'«2 P*WAR PdZ�vS
axv19Loc 4b 2 �
1
SPACe b4c TP-ub%jcTZpN
r
(,(o,z�� �bIL-V, 6K f3, z�s mid
DAi�y t1Au = 3(o, 2-H 8 Jl ,, ""i-
�+ KeAw- -r IN 'P�21y
`�i1S YJQ�D -D
NNkrJ� N RE5��2� 24C{ HT -No
-1kA� r^L4 FORYt e� 9.11 T121 t�V Si1A `� , I F ��X 6-1 r Lilt, crs�
-• YI�\eIL.IT�I }� IIV�,L,�j� Wl PQPLIept'\1Ot�► �J,ITYZ-1tJVT
�C(,L2 ekttLy DOIKb -NMYS 70 SwDGri
►�H'[i �LD�b
71JI IC\�} (o -?(!tN • `i>ee--t t r ISSVof�
70TA\.-CI->_rLo►,(W-k,

OEM> SfeXxcOIDR- L�C -A-'�ucy
E,
i u I2-cE5kn UT�qy t-
513Ih(, NU4
G3—cF�-3b
3)p = CP3 to Ake S w GFs -1 Qt U I a S
o lf�1U-22R 3DCZ2-
CLAkss T-117 -,uri-N i
11,.E — ' -I 0 CFe-q \ 0 _70 SAV O-�(=�
U eZPOK DON�� iZFh C*j ',
tZlzz\ q`1 Np� -For fox � \uYe,
ZtZtila� �� •• �ccos cmlt�oryti clou\y mo-xv;oV
-zlz N.0 for �a� ��xc� w�w.� c r UI L �`i lq i
-ivwc;4-y
�lD cco�� 2-1
(CUP)

SECRETARY
NORTH CAROLINA DEPARTMENT OF
ENVIRONMENT AND NATURAL RESOURCES
]VISION OF WATER Q ITY
T+�1 SV vlefl (D ml It_
wkhro - 2nt L
TP yoc-gv'� -Lf*�II.
FbP- O.S-RCtb
45ldo.l5 1b
j2"`11L4 0.5-vtc,b g.3`IS60.Oq IvsId �ga_s dw
913aP3
-i'�' Imdlr_�O�Si-t�0�z S.3y: �I.I-Illn/�
fbp- s'o "L !
G �J�`� 4130?13 1►u IZ� I� _ 18 a 6�{ , b I b s
tS1 % MAIL SERVICE CENTER, RALEIGH, NORTH CAROLINA 27699-1617
website: h2o.enr.state.nc.us PHONE [phone] FAX [phone]
AN EQUAL OPPORTUNITY/ AFFIRMATIVE ACTION EMPLOYER - 50% RECYCLED/10% POST -CONSUMER PAPER

GARNEPoRALEIGN WATER AND SEWER UTRITY MERGER
MEMORANDUM OF AGREEMENT
c) Construct a new wastewater treatment facility and discharge the effluent to the
main stem of the Neuse River.
It is mutually agreed that for 75 mgd, the NPDES permit limits for BODS and NH3-N for
the Neuse River WWTP will be established as follows:
a) BOD5 limits of 5 mg/L in summer and 10 mg/L in winter
b) NH3-N limits of 1 mg/L in summer and 2 mg/L in winter
7) It is mutually agreed that the improvements to 75 mgd will be implemented at the Neuse
River WWTP in accordance with a schedule defined by the City of Raleigh. It is further
agreed that the NPDES permit limits for BOD5 and NH3-N at 75 mgd will become `
effective upon achievement of all of the following conditions: `
\ a) The City of Raleigh submits to DWQ a certificate of completion documenting that the
!�["Q improvements to 75 mgd for the Neuse River WWTP are complete, and
A" ) The average monthly effluent flow from the Neuse River WWTP exceeds 60 mgd. As
part of this condition, the City of Raleigh agrees to submit a certified letter to DWQ's
IQQ designated representative within 30 days following the first month that the average
monthly effluent flow from the Neuse River W WTP exceeds 60 mgd. The letter will
commemorate the following for DWQ:
(i) The average monthly effluent flows from the Neuse River WWTP have exceeded
60 mgd
Q 1I,n (iWWTP
The City has complied with the 75 mgd permit conditions for BOD5 and NH3-N
O' V =� during the month that the average monthly effluent flows from the Neuse River
jj � /\ W TP exceeded 60 mgd
to Gjk� "U l (iii) The City of Raleigh has initiated treatment process and operational changes to
l comply with the 75 mgd permit conditions for BOD5 and NH3-N for all future
months.
Consistent with existing policies, an extreme hydrological event will be considered an
upset in accordance with Part II (5) of the NPDES permit and not trigger the
requirement above.
Wastewater Collection System Operation and Performance
The Town of Gamer wastewater collection system is comprised of an estimated 99 linear
miles of gravity sewers, 20 miles of force mains, 23 wastewater pump stations, and over
2,600 manholes. Since 1989, the Town of Garner has recorded 52 system overflows for the
wastewater collection system.
Upon execution of the merger Agreement, the City of Raleigh will assume immediate and
sole duty and responsibility for operating, maintaining, improving, and expanding the
wastewater collection system serving the Town of Garner's existing and future corporate
limits and Urban Services Area. It is understood that these duties and responsibilities will
PAGE?

PHARR YARNS, INC. WWTP
TOTAL NITROGEN LEVELS JAN. 1998 - DEC. 2000
MONTH
LIMIT
AVERAGE
MAXIMUM
MINIMUM
Jan-98
6.0
7.16
12.34
4.37
Feb-98
6.0
19.89
28.57
3.66
Mar-98
6.0
14.04
18.72
8.26
A r-98
6.0
18.70
31.85
8.79
Ma -98
6.0
10.20
14.94
7.00
Jun-98
6.0
28.13
37.17
19.49
Jul-98
6.0
30.69
45.58
17.97
Au -98
6.0
12.54
15.49
9.32
Se -98
6.0
14.00
16.32
12.39
Oct-98
6.0
12.51
21.07
5.26
Nov-98
6.0
4.48
7.09
2.04
Dec-98
6.0
6.29
8.75
4.73
Jan-99
&0
5.10
7.10
3.22
Feb-99
6.0
4.40
5.41
3.21
Mar-99
6.0
4.21
5A8
2.74
A r-99
6.0
14.96
21.02
12.15
Ma -99
6.0
18.27
19.69
17.37
Jun-99
6.0
22.71
33.47
13.10
Jul-99
6.0
15.86
20.38
11.45
Au -99
6.0
14.81
19.70
5.54
Se -99
6.0
7.90
10.60
6.10
Oct-99
6.0
14.31
16.93
11.10
Nov-99
6.0
7.02
8.82
5.81
Dec-99
6.0
7.76
8.30
6.97
Jan-00
6.0
11.10
14.65
7.49
Feb-00
6.0
13.46
19.44
8.09
Mar-00
&0
5.58
7.17
4.83
A r-00
6.0
12.18
15.72
4.87
Ma -00
6.0
26.57
30.09
22.74
Jun-00
6.0
15.02
21.32
5.40
Jul-00
6.0
17.88
21.68
14.73
Au -00
6.0
13.26
15.89
8.69
Se -00
6.0
16.53
18.00
14.49
Oct-00
6.0
16.55
17.51
16.14
Nov-00
6.0
18.95
32.90
11.70
Dec-00
6.0
28.17
29.70
26.00

35
30
25
►Zq
15
10
TOTAL NITROGEN PHARR YARNS WWTP
a0 cp a% 0 o° ' ' o°' o°' ao �cP sP o° o0 00 00
� QQ )Jc P OZ` peg Qz
DATE
■ LIMIT
❑ AVERAGE'

MAKE-UP OF PHARR YARNS
WASTEWATER FLOW BY PERCENT
COMPLEX-46
UNIT-23
1-85 DIVISION
SPACE DYE
DATE
DOMESTIC
DOMESTIC
DOMESTIC
INDUSTRIAL
Oct-99
42.90%
41.20%
5.10%
10.80%
Nov-99
43.80%
27.50%
6.60%
22.10%
Dec-99
40.00%
30.00%
6.60%
23.40%
Jan-00
49.80%
16.40%
5.00%
28.80%
Feb-00
53.00%
30.00%
6.00%
11.00%
Mar-00
62.10%
17.30%
7.20%
13.40%
A r-00
74.00%
1.20%
8.00%
16.80%
Ma -00
81.80%
8.60%
7.70%
1.90%
Jun-00
75.00%
8.00%
5.00%
12.00%
Jul-00
60.00%
23.00%
5.00%
12.00%
Au -00
26.60%
23.20%
5.60%
44.60%
Se -00
27.90%
9.80%
2.00%
60.30%
Oct-00
43.00%
18.90%
2.50%
35.60%
Nov-00
39.50%
14.20%
2.50%
43.80%
Dec-00
54.00%
9.50%
3.10%
33.40%
Jan.-01
49.00%
9.00%
2.00%
40.00%
Feb.-01
39.00%
9.00%
2.00%
50.00%
TOTAL DOMESTIC: 73.00%
TOTAL INDUSTRIAL: 27.00%

PHARR YARNS WWTP
EFF.
FLOW JAN.98 - DEC. 00
DATE
AVG.
MAX.
MIN.
PROP. LIMIT
MGD
MGD
MGD
MGD
Jan-98
0.070
0.145
0.015
0.500
Feb-98
0.065
0.130
0.014
0.500
Mar-98
0.060
0.120
0.007
0.500
A r-98
0.049
0.141
0.002
0.500
Ma -98
0.045
0.100
0.009
0.500
Jun-98
0.046
0.100
0.009
0.500
Jul-98
0.047
0.111
0.010
0.500
Au -98
0.048
0.090
0.005
0.500
Se -98
0.055
0.140
0.006
0.500'
Oct-98
0.086
0.147
0.018
0.500
Nov-98
0.099
0.168
0.019
0.500
Dec-98
0,097
0.250
0.000
0.500
Jan-99
0.098
0.154
0.043
0.500
Feb-99
0.088
0.153
0.03
0.500
Mar-99
0.086
0.151
0.023
0.500
A r-99
1 0.071
0.175
0.017
0.500
May-991
0.081
0.180
0.017
0.500
Jun-99
0.080
0.178
0.042
Q.500
Jul-99
0.056
0.134
0.000
0.500
Au -99
0.144
'0.420
0.042
0.500
Se -99
0.088
0.149
0.019
0.500
Oct-99
0.094
0.153
0.028
0.500
Nov-99
0.075
0.229
0.026
0.500
Dec-99
0.080
0.162
0.000
0.500
Jan-00
0.086
0.165
0.000
0.500
Feb-00
0.079
0.143
0.032
0.500
Mar-00
0.058
0.125
0.012
0.500
A r-00
0.054
0.199
0.014
0.500
Ma -00
0.055
0.093
0.01.1
0.500
Jun-00
0.092
0.121
0.041
0.500
Jul-00
0.059
0.140
0.000
0.500,
Au -00
0.055
0.093
0.011
0.500
Se -00
0:106
0.203
0.023
0.500
Oct-00
0.097
0.175
0.031
0.500
Nov-00
0.099
0.237
0.032
0.500
Dec-00
0.074
0.180
0.052
0.500

M.
0.5
0.4
0.2
[IN
PHARR YARNS EFFLUENT FLOW
C� A� 0 CP aw CP CP a� 59 CP CP o0 60 0p 00 00 00
,ac
DATE
-AVERAGE
-MAXIMUM
MINIMUM
PROPOSED LIMIT

3'
O
m(O
N'V
M(00
000
V
(O
V
NM
N
U)
N
N
O
O
O
�-(O
m(O
M
M
M
M
i�O
N
N
(O
O
N
I-
�
O
N
N
V
m
r�
(O
00
M
00
O
N
N
I-
LO
O
V
N
m
I-
�
LO
r
N
M
M
O
ON
(O
R
CO
N
0
0
0
0
0
0
0
0
0
0
p
0
0
66
0
0
0
0
0
Ncn
O
O
O
O
O
ao
(()
m
m
m
r
0,
m
V
m
.-
r�
M
N
r-
U)
(D
M
co
LO
0
m
N
m
M
t-
N
m
V
O
N
r
O
W
N
N
UO
tO
(O
M
m
N
U)
O,
U-)
O
O
m
(O
ro
V
O
(O
M
(O
M
m
0
(O
N
I1-
O,
q
_
�
V
V
(O
�
00
�
V
O
O
N
N
,
N
(O
r
CO
V
M
N
N
(V
M
V
N
N
W
J
to
U
M
W
w
�
2
a
_
=
LU
cn
H
Z
�
1-
M
N
0
0
0
V
(O
N
O
(O
(0
N
O
r
M
m
m
M
v
m
w
m
V
O
M
N
M
m
O
M
T
0
00
co
O
O
(O
N=
f,-
Nt'-
U')
V,
V
I-
m
m
CO
M
M
m
I-
00
O,
N
Nt
,
M
O
O
r-
m
N
M
(O
�U-)
(
n
0
0
11010
O
(N
O
N
O
1
N
N
CO
a
;
a
a
J
H
O~
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
(D
O
O
O
O
O
O
O
O
O
2
999999999900000000000000000000000000
=
W
00
CO
00
OCD
CO
00
W
00pMmmmmmmmmmmmm00000pO00pOO
F'
M
O)
m
C)
m
m
m
O)
O)
m
0)
C�
O)
Cn
m
O)
m
m
m
Q)
m
Q1
O)
p
0
0
0
0
p
p
0
0
p
0
0
z
C
Ccm
a
>
U
C
-0
C
>
U
C
Q
C
>
U
O
N
N
O
O7
3
7
zi
0)
U
O
0)
(p
0)
O7
(0
O
�
0
0)
U
0
0)
m
0)
@
0)
7
�
7
0)
U
0
0)
g
�(Li<
<(n0zo�LL
�Q(n0z0
U-
<
--
�Q<00ZO

• m
m
VLdd
3 11
5.00
ME
3.00
2.00
1.00
MI
TOTAL PHOSPHORUS PHARR YARNS WWTP
�J 5ed 1 °0 -Sacs° le 40 s°�
DATE
IMLIMIT
L AVERAGE

SOC PRIORITY PROJECT: No
To: Permits and Engineering Unit
Water Quality Section
Attention: Natalie Sierra
Date: May 23, 2001
NPDES STAFF REPORT AND RECOMMENDATIONS
County: Gaston
NPDES Permit No.: NC0004812
MRO No.: 01-78
PART I - GENERAL INFORMATION
2.
4.
Pj
7
Facility and Address: Pharr Yams WWTP
101 Main Street
Post Office Box 1939
McAdenville, N.C. 28101
Date of Investigation: May 15, 2001
Report Prepared By: Michael L. Parker, Environ. Engr. II
Iij� I MAY 3 0 2001
_ ..,.tcv OUALIV
Person Contacted and Telephone Number: Mike Church, [phone].
Directions to Site: From the jct. of Hwy. 7 and I-85 in eastern Gaston County, travel
south on Hwy. 7 = 0.2 mile and turn left on Dickson Drive (no SR number). The WWTP
site is on the left side of Dickson Drive after traveling 0.2 mile.
Discharge Point(s), List for all discharge Points: -
Latitude: 350 15' 40"
Longitude: 810 04' 39"
Attach a USGS Map Extract and indicate treatment plant site and discharge point on map.
USGS Quad No.: F 14 SE
Site size and expansion area consistent with application: Yes. Limited area is available
for expansion, if necessary.
8. Topography (relationship to flood plain included): The WWTP site did not appear to be
located in the 100 year flood plain (many of the primary treatment units were elevated
and protected from flooding by a concrete wall).
9. Location of Nearest Dwelling: Approx. 200f feet from the WWTP site.

Page Two
10. Receiving Stream or Affected Surface Waters: South Fork Catawba River
a. Classification: WS-V
b. River Basin and Subbasin No.: Catawba 030834
C. Describe receiving stream features and pertinent downstream uses: Excellent
flow in the receiving stream. Down stream uses are fish and wildlife propagation,
secondary recreation, and agriculture.
PART II - DESCRIPTION OF DISCHARGE AND TREATMENT WORKS
1. a. Volume of Wastewater: 1.0 MGD (Design Capacity)
b. What is the current permitted capacity: 1.0 MGD. Requested permitted capacity:
0.500 MGD (See Part IV)
C. Actual treatment capacity of current facility (current design capacity): 1.0 MGD
d. Date(s) and construction activities allowed by previous ATCs issued in the
previous two years: N/A
e. Description of existing or substantially constructed WWT facilities: The existing
WWT facilities consist of a bar screen followed by an aeration basin with fixed
floating aerators, polymer and alum addition, two (2) clarifiers, flow measurement
(continuous flow recording device with totalizer), three (3) mixed media pressure
filters, four (4) sludge thickening tanks, sludge centrifuge, a belt filter press, and
chlorine disinfection with contact basin. This facility has two power sources
(Duke Power and the adjacent mill).
f. Description of proposed WWT facilities: There are no proposed WWT facilities at
this time.
g. Possible toxic impacts to surface waters: Chlorine is added to the waste stream.
This facility has consistently passed its toxicity testing.
h. Pretreatment Program (POTWs only): Not Needed.
2. Residual handling and utilization/disposal scheme: Residuals are currently thickened and
then processed in a belt filter press. PY obtained approval to conduct a pilot study on
static -pile composting of their residuals, however, so far they have been unable to
maintain the proper temperature to achieve the necessary pathogen reduction. PY has
applied for a Distribution and Marketing Permit for the disposal of their residuals.
3. Treatment Plant Classification: Class II (formally Class III). Facility has requested a
change in permitted flow, which will result in a change in the facility classification (see
Part IV).
4. SIC Code(s): 2262 Wastewater Code(s): 55 MTU Code(s): 05602

Page Three
PART III - OTHER PERTINENT INFORMATION
Is this facility being constructed with Construction Grant Funds or are any public monies
involved (municipals only)? No
Special monitoring or limitations (including toxicity) requests: None at this time.
Important SOC/JOC or Compliance Schedule dates: N/A
Alternative Analysis Evaluation: There is no reasonable alternative for this facility.
Municipal sewer of sufficient capacity to accept this waste flow is currently unavailable to
this site. Spray/Drip Irrigation and/or subsurface disposal is not an option due to the lack of
sufficient area.
PART IV - EVALUATION AND RECOMMENDATIONS
Pharr Yarns (PY) requests renewal of the subject Permit. During this renewal, PY has
requested a change in the permitted effluent flow from 1.0 MGD to 0.500 MGD. Recent reductions
in influent flow has resulted in (3 year) average daily flows of 0.076 MGD, far less than the current
hydraulic capacity. Although PY has picked up additional domestic flow from Plant's 46 and 23,
the additional flow has resulted in only a slight increase in total flow to the existing WWTP. PY
would, however, like to retain the option of having effluent limits for 1.0 MGD remain in the permit
should production at the mills served by this facility increases or additional wastewater sources are
connected such as the Town of McAdenville or the Town of Lowell.
PY had previously been contacted by the Division regarding the possibility of nutrient limits
being included in the permit upon renewal. As a result, PY evaluated their treatment process to
determine whether the existing WWT facilities could comply with the anticipated nutrient limits
(1.0 mg/1 TP and 6.0 mg/l TN) without additional modifications and/or upgrade. Based on this
evaluation, PY has concluded that additional modifications would be necessary in order to comply
with the projected nutrient limits. Such being the case, if nutrient limits are to be incorporated into
this permit at renewal, either a compliance schedule will need to be included in the permit or the
nutrient limits will need to be phased in. Once it is determined that nutrient limits will be applied to
this permit at renewal, PY should be advised so that the appropriate amount of time can be included
in the permit to allow for the necessary modifications.
Pending receipt and approval of the WLA, it is recommended that the Permit be renewed as
requested. C A I ^ _
f'= 23 -z:2
Signature of ReporrPreparer Date
Water Quality R nal Supervisor Date
h: \dsr\dsr01 \pharyam. dsr

Pharr-Pilonmr
Pharr International, Inc.
Sylvonlo Yam Systems, Inc.
PHARR
YARNS
Pharr Yarns, Inc.
P.O. Box 1939
100 Main Street
McAdenville, NC 28101.1939
Telephone: [phone]
Facsimile: 704/824-0072
April 3, 2001
Ms. Valery Stephens
NCDENR
Division of Water Quality
Point Source Branch
1617 Mail Service Center
Raleigh NC 27699-1617
Subject: Pharr Yams Industrial WWTP
NPDES Permit Renewal Request
Permit No. NC0004812
Gaston County NC
Dear Ms. Stephens,
Pharr Yams, Inc. requests the renewal of our subject permit, which will
expire on September 30, 2001. Please find attached the NPDES Application
Form, Standard Form C, including supplemental documentation appendices.
Since our permit was issued in 1996 we have accepted additional waste-
water flow from two other Pharr Yarns facilities, which previously discharged
to the Town of Lowell W WTP. Sewer collection systems and pumping
stations were constructed and began operation on October 8, 1999. Domestic
wastewater from the facilities, Complex 46 and Unit 23 have changed the
characteristics of the total influent concentration and activated sludge
treatment process. The operation of our existing wastewater treatment has
been modified to enhance treatability and efficiency of the increased percentage
of domestic wastewater. The previous 1.0-MG pretreatment basin is now
used for extended aeration and the previous 1.0 MG extended aeration basin
is now an aerobic digester.
Due to the historical and present average effluent flow rate, past 3 year
average = 0.076-MGD, and Space Dye production rates for the last three
years, as referenced in the attached production rate sheet, averaged 66,277
pounds per week or 13,255 pounds per day based on a 5 day work week,
with a daily maximum of 36,248 pounds on June 14, 2000,we would like to
request that the permitted average daily flow of 1.0-MGD be changed to
a permitted average daily flow of 0.5 MGD.
According to G.S. 9OA-37 Section .302(b) Systems that utilize an activated
Sludge or fixed growth process, with a permitted flow less than or equal to
0.5 MGD shall be assigned as a Grade H Biological Water Pollution Control

Phargalomor
Phan Yarns, Inc.
Pharr International, Inc.
P.O. Box 1939
Sylvania Yarn Systems, Inc.
100 Main Street
McAdenville, N( 28101-1939
Telephone: [phone]S I
Facsimile: 704/824-0072
System. However, the WWTP is designed for 1.0-MGD and we would like
to reserve the option to submit a requ
est for modification of the permit to
return to 1.0-MGD if a need arises. Factors that could cause an increased
flow would include increased Space Dye yam production or acceptance
of flow from the Town of McAdenville and/or the Town of Lowell's W WTPs.
A nutrient study report was submitted on October 28,1999 to the Water
P H AR R Quality Section -Technical Support Branch as required in Part III Section F
Y A R N S of our permit which investigated the feasibility of meeting monthly total
phosphorus averages of 1.0 ppm and summer average limits of 6.0 ppm on
total nitrogen. As described in the study and indicated on the attached charts
we believe that total phosphorus can be reduced with our current aluminum
sulfate and polymer flocculant. Total nitrogen can be significantly reduced
with addition of the proposed aerators and mixing equipment. Additional
operation under actual conditions are needed to assure we can comply
with proposed 6.0 mg/1 limits. Because of these unknown factors, if effluent
limits for total phosphorus and nitrogen are included in the new permit we
request that the limit be calculated on the plants design flow of 1.0-MGD
using mass based pounds per day average monthly limits.
Please contact me at [phone] if any other information is needed.
Respectfully Submitted,
Mike Church
Environmental Engineer

PHARR YARNS INDUSTRIAL WWTP
PERMIT NO. NC0004812
INFLUENT WASTEWATER CAPACITIES AND PERCENT OF
TOTAL FLOW FROM OCT. 8, 1909 THRU FEB. 2001
FACILITY
NAME
WASTEWATER
TYPE
PUMP STATION
CAPACITY
FLOW
%
MAX. AVERAGE
FLOW RATE
SPACE DYE
INDUSTRIAL
700 gpm
27.00%
60.30%
COMPLEX-46
DOMESTIC
200 gpm
50.70%
81.80%
UNIT-23
DOMESTIC
100 gpm
17.50%
41.20%
1-85 DIVISION
DOMESTIC
I GRAVITY
1 4.80%
1 7.70%
PRESENT OPERATING STATUS
* 1.0 M.G. Extended Aeration Basin
* Alum and Polymer Addition for Flocculation
*Two Parallel Clarifiers, 1: 41 ft Diameter, 100,000 gallons,
2: 35 ft Diameter, 72,000 gallons
* Two Return Sludge Pumps, 350 gpm Each
* Filter Pump Wet Well with Two 700 gpm Pumps
* Three 8 ft Diameter Mixed Media Filters
* Tablet Type Chlorinator
* Dual Chlorine Contact Chamber, 12 ft X 30 ft X 10 ft
* 1.0 M.G. Aerobic'Digester
* 6,800 Gallon Sludge Thickening Tank
* 1 Meter belt Press
* Sludge Composting/Storage Facility, 120 ft X 50 ft.

MAKE-UP OF PHARR YARNS
WASTEWATER FLOW BY PERCENT
COMPLEX-46
UNIT-23
1-85 DIVISION
SPACE DYE
DATE
DOMESTIC
DOMESTIC
DOMESTIC
INDUSTRIAL
Oct-99
42.90%
41.20%
5.10%
10.80%
Nov-99
43.80%
27.50%
6.60%
22.10%
Dec-99
40.00%
30.00%
6.60%
23.40%
Jan-00
49.80%
16.40%
5.00%
28.80%
Feb-00
53.00%
30.00%
6.00%
11..00%
Mar-00
62.10%
17.30%
7.20%
13.40%
A r=00
74.00%
1.20%
8:00%
16:80%
Ma -00
81.806/o
8.60%
7.70%
1.90%
Jun-00
75.00%
8.00%
5.00%
12.00%
Jul-00
60.00%
23.00%
5.00%
12.00%
Au -00
26.60%
23.20%
5.60%
44.60%
Se -00
27.90%
9.80%
2.00%
60.30%
Oct-00
43.00%
18.90%
2.50%
35.60%
Nov-00
39.50%
14.20%
2:50%
43.80%
Dec-00
54.00%
9.50%
3.10%
33.40%
Jan.-01
49.00%
9.00%
2.00%
4.0..00%
Feb.-01
39.00%
9.00%
2.,00%
50.000/0
TOTAL DOMESTIC: 73.00%
TOTAL INDUSTRIAL: 27.00%

PHARR YARNS WWTP
EFF.
FLOW JAN.98 - DEC. 00
DATE
AVG.
MAX.
MIN.
PROP. LIMIT
MGD
MGD
MGD
MGD
Jan-98
0.070
0.145
0.015
0.500
Feb-98
0.065
0.130
0.014
0.500
Mar-98
0.060
0.120
0.007
0.500
�A r-98
0.049
0.141
0.002
0.500
Ma -98
0.045
0.100
0.009
0.500
Jun-98
0.046
0.100
0.009
0.500
Jul-98
0.047
0.111
0.010
0.500
Au -98
0.048
0.090
0.005
0.500
Se -98
0.055
0.140
0.006
0.500
Oct-98
0.086
0.147
0.018
0.500
Nov-98
0.099
0.168
0.019
0.500
Dec-98
0.097
0.250
0.000
0.500
Jan-99
0.098
0.154
0.043
0.500
Feb-99
0.088
0.153
0.03
0.500
Mar-99
0.086
0.151
0.023
0.500
A r-99
0.071
0.175
0.017
0.500
Ma -99
0.081
0.180
0.017
0.500
Jun-99
O.Q80 ,
0.178
0.042
0.500
Jul-99
0.056
0.134
0.000
0.500
Au -99
0.144
0.420
0.042
0.500
Se -99
0.088
0.149
0.019
0.500
Oct-99
0.094
0.153
0.028
0.500
Nov-99
0.075
0.229
0.026
0.500
Dec-99
0.080
0.162
0.000
0.500
Jan-00
0.086
0.165
0:000
0.500
Feb-00
0.079
0.143
0.032
0.500
Mar-00
0.058
0.125
0.012
0.500
A r-00
0.054
0.199
0.014
`0.500
Ma -00
0.055
0.093
0.011
0.500
Jun-00
0.092
0.121
0.041
0.500
Jul-00
0.059
0.140
0.000
0.500
Au -00
0.055
0.093
0.011
0.500
Se -00
0.106
0.203
0.023
0.500
Oct-00
0.0,97
0.175
0.031
0.500
Nov-00
0.099
0.237
0.032
0.500
Dec-00
0.074
0.180
0.052
0.500

PHARR YARNS EFFLUENT FLOW
w
0.5
GL!
0
C7
i
0.3
O
J
LL
0.2
0.1
OP ,ac �a� �a� �� 0e� ��, ,ac �a� �a1 �; C50 �o� sac 4a 1 a0 �J 41,
DATE
AVERAGE
MAXIMUM
MINIMUM
PROPOSED LIMIT

PHARR YARNS, INC. WWTP
TOTAL
NITROGEN LEVELS JAN. 1998 - DEC. 2000-
MONTH
LIMIT
AVERAGE
MAXIMUM
MINIMUM
Jan-98
6.0
7.16
12.34
4.37
Feb-98 -
6.0
19.89
28.57
3.66
Mar-98
6.0
14.04
18.72
8.26
A r-98
6.0
18.70
31.85
8.79
Ma -98
6.0
10.20
14.94
7.00
Jun-98
6.0
28.13
37.17
19.49
Jul-98
6.0
30.-69
45.58
17.97
Au -98
6.0
12.54
15.49
9.32
Se -98
6.0
14.00
16.32
12.39
Oct-98
6.0
12.51
21.07
5.26
Nov-98
6.0
4.48
7.09
2.04
Dec-98
6.0
6.29
8.7,5
4.73
Jan-99
6.0
5.10
7.10
3.22
Feb-99
6.0
4.40
5.41
3.21
Mar-99
6.0
4.21
5.48
2.74
A r-99
6.0
14.96
21.02
12.15
Ma -99
6.0
18.27
19.69
17.37
Jun-99
6.0
22.71
33.47
13.10
Jul-99
6.0
15.86
20.38
11.45,
Au -99
6.0
14.81
19.70
5.54
Se -99
6.0
7.90
10.60
6.10
Oct-99
6.0
14.31
16.93
11.10
Nov-99
6.0
7.02
8.82
5.81
Dec-99
6.0
7.76
8.30
6.97
Jan-00
6.0
11.10
14.65
7.49
Feb-00
6.0
13.46
19.44
8.09
Mar-00
6.0
5.58
7.17
4.83
A r-00
6.0
12.18
15.72
4.87
Ma -00
6.0
26.57
30.09
22.74
Jun-00
6.0
15.02
21.32
5.40
Jul-00
6.0
17.88
21.68
14.73
Au -00
6.0
13.26
15.89
8.69
Se -00
6.0
16.53..
18.00
14.49
Oct-00
6.0
16.55
17.51
16.14
Nov-00
6.0
18.95
32.90
11.70
Dec-00
6.0
28.17
29.70
26.00

TOTAL NITROGEN PHARR YARNS WWTP
35
30
25
`Z1
❑AVERAGE
15
10
,��' gyp° c� A° o°
40 Qe Q� )� PJ« O° O� Qe PQ )J PJ� �� O� Qe PQ s1 Q� O°�
DATE

vZpv�Dr
mDKMC
(D
�:
1
O
C
1
n
rt
1
O
CD
1
C
1
C.
j
O
I
O
!v
I
1
o
N
1
1
o
(D
1
N
I
O
CD
n
1
06
0
C
1
n
rt
I
co
CD
1
C
1
C
O
C
1
O
N
1
1
O
N
'�
1
w
(D
Q
1
!v
1
O
-CD
�:
1
O
C
1
n
rt
1
O
(D
I
C
1
C
j
W
C
I
O
0)
1
-
1
0
p)
-
1
0
(D
1
0
1
0
O
O
000000O000.000OCDmoCOCDWW
O
o
O
O
O
O
co
Cfl
O
ocoWWWMmmODaDaDaDOODm
0
w
0
W
W.
W
=
as
0000o0000000o0OOOOoOioOOOOOOOOOOOOOOO
00000000000000000-o0000.o.o000000000000
O
`D
r
z=
-
-
-�-L
-L
W
O�ONOO
O�
.00
—
V
CnV
W
C
m
O—xLNN—LN-
VOO--LOD—p
.N-
CO
D
CO
CO
CO
O
VN)0
.—.pCnVV
Cll000NW
V--
V
OO—
o0OOD00o
COpWOCO04NW
m
_
M
m
c
0
�00
n�
�m
WNK)
N)WJiW
v
-LW
L.
o0-t,
-M
jW
��
cri
=
�
iDlOVNnOOOODCO.A
O
NOD(0'1WCON
Co0CJi
OCOO—OCn--ODCnNC0CA)Ul
00-4MW
11
N
co
CD
m
r
O
O
O
O
O
N
0
0
0
0�
0
0
0
0."
O
o
O
O
O
o
0
0
0
0
0
0
N
W.
-
P
C n
N
0
- O
r
WGJk):-46
NOV�WCDCflW—OC.00
V000D
AOCitVNN0N)MCD
-OO.W
CnCD0
�WtVCD-4w
4�klCnD.000OOW
IANNO
-4
NCnCD
00
OD
O

W�
ME
7.00
m
5.00
4.00
3.00
2.00
1.00
ixiD,
TOTAL PHOSPHORUS PHARR YARNS WWTP
0 s; 44 o" 10 �1 5o, Sac 10 10 13 5e11
DATE
E LIMIT
OAVERAGE'

PHARR YARNS INDUSTRIAL WWTP
NPDES PERMIT NO NC0004812
POTENTIAL MODIFICATIONS TO TREATMENT PROCESS
Nutrient removal equipment may be required to reduce total nitrogen concentrations
in the plant's effluent discharge.
The required design and construction applications will be submitted if the need
arises.

PHARR YARNS, INC.
WWTP FLOW DIAGRAM
NPDES NO. NC0004812
+11,
J AG AirE+rorw AcR4nJo
AP x 1-0 NJaFAa*rfwA,4FQAraRJ 4S19182'
�AGXWAJN rq2 oye Anrr
3-MIXED MEDIA W6FILTERS
�1�
EfL j
rl
1 _
1 RETURN SLUDGE 1
K
Mai A60150I6 01663TEA
u�T[ X 7 S N P -iveo ABOATDiP!
LUDGE S' A pen
SLUDGE
iN IC11E1rIH®,
Sol, 10
.Iow7-5 �rf
CNL0"IKE
CO�M;�Ct
�l

_ PHARR YARNS, INC.
SPACE DYE DIVISION NPDES PERMIT NO. NC-0004812
3 YEAR PRODUCTION DATA
Week EfkMV
Pounds
Week Ending,
Pounds
WwK Ending
Pounds
MApr 1998
40,35+4
02,Apr 1999
65,557
31-Mar 2000
74.898
10-Aw
22,783
"r
'71,283
07Apr
41.603
17-Apr
75.819
53,151
244K
26.271
Z3Apr
n112
214W
M774
014ft
72.574
3 "W
37,ti64
28 Apr
74.680
-08-may
41,563
07•Mey
54.901
OSAUy
66.744
is -may
64.866
14Aay
38,435
12-fr
3KOW
224fty
MAW
21Afty
sg;954
Isfty
65.341
294"
08.148
2""
30.027
28-AIRY
53A0B
054un
84,611
04,tun
24,9W
02,Jun
79,OB7
12 Jan
82.887 --
11-Ark
22.122
08+6M
1KZ10
lb -Jun
71,481
18-im
75MO
161m
144,424
2&Ju1
.18,700
25-Jun
63,316
23Am
7%526
10-M
70.035
02-Jui
34,4164
30-Jun
76.078
17-Jul
45„ 167
1i6m
41.WS
14JLJ
43.679
24-4d
78,,084
23Jul
41.943
2Ulyd
84,116
31-Jul
81,223
30•.h!
18,154
254W
'82.101
07 Aug
82.246
0&Aug
28.824
04 "
61.326
144W
63,087
13-Aug
, 55,693
11AW
54,561
21-ft
63,454
20-Aug
+49,824
1$^Q
49,048
Z&Aug
58.927
974%W
4Z465
25-Aug
M734
04Sep
56.742
W-ft
31LO43
014ep
SZ.243
11-sep
80.359
fOSep
-0.486
08Sap
44.00
15•Sep
79,277
1746p
75.135
154kp
87.E
2&8ep
97.069
24-W
60,409
22-Sep
44.217
02-Od
71.446
01.Oct
75,596
29Sep
00,209
O&Dd.
55.m
08-Od
W52
084at
44,290
58.133
154t
60;o
134d
67.765
2
22-M
5%747
204OCt
102.557
30-Od
C 102.64V.
29-Oct
58,452
27-Od
77,204
06-Nov
60.932
05-Nov
34,403
03-Nov
88.=
134%v
42.888
.12-Nov
79.706
10-NOV
97.319
20MNOv
62.90
19-Nov
71.368
17-Nov
73.278
27-MOV
63.256
2541m
X09
24-Nou
57.394
04-0ec.
81.169
03 4DW
40AN
01-04c
38.902
11-0ec
64,613
10-08c
81,119
obam
W077
1B-Dec
51.087
174Dea
38.697
1543se
114.326
01,dan 1999
48,586
24-DOG
3n.=
22-Dec
60,329
06-Jen
53,130
07-JIM 2000
44.830
OSJan 2001
W929
16,dan
94,068
f4Jan
48.640
12,1an
101.=
22 an
ii5.OS0
2i-im
63,747
194M
89:63l;
28-Jan
24.882
28-Jan
70.610
28-Jan
106.745
05-Feb.
124.299
04-Feb
29.200
02-Feb
73 m
12-F4b
12Z 57
11-Feb ''
63.527
09-Feb
100,21m
19-Feb
75.360
IlWeb
43.160
18-Feb
12l,3U
26-Feb
17A,247
25-Feb
SA542
23-Feb
107.887
054W
112,877
03mv
49,600
024ftr
117AN
124W1sr
132,530 —
104ar
40,874
09JAW
109,453
IS-Mor
116.124
17-Mer
34,247
154ft
130,019.
204tar
110,752
2441ar
40,491
234br
T0101 W99
3.645,260
Total99-M
2,501.006
Total 004m
3,719.348
Aveme Per wrNc
72.905
Akarapa per week
50.020
Amw perwisak
MNS
ma*num perweek
132,530
ma+dmum -y VAN3K
31.119
t mflnum pervmek
144,424
MAX M M DAILY PRODUCTION DURING THE PAST 3 YE
36,248 POUNDS ON JUNE 14, 2000 r

4-YJ3-GIUYJ I I W : 44Nr1 r mwri r-mm - , . ------
w...
R
PA
roRrEs. rnrc.
www.pa a s.com
Attn: MIKE CHURCH
PHARR YARNS
PO BOX 1939
McADENVILLE, NC 28101-
PAR Laboratories, Inc.
2217 Graham Park Drive
PO Box 411483
Charlotte, NC 28241-1483
NOC 2o; SCCerffi99003001
REPORT OF ANALYSES
PROJECT NAME: MAR 01
DATE: 03/29/01
SAMPLE NUMBER- 29383 SAMPLE ID- PHARR IWTP EFF COMP
DATE SAMPLED- 03/21/01 LOCATION, IWTP
DATE RECEIVED- 03/21/01 SAMPLER- DON COLLEY
TIME RECEIVED-- 1300 DELIVEREZ BY- GREG JOHNSON
Page 1
ANALYSIS
AMMONIA NITROGEN
1KOELDARL NITROGEN
NITRATE/NITRITE
TOTAL PHOSPHOROUS
CHROMXUM, TOTAL
ACROLEIN•AND ACRYONITRILE
ACROLEIN
ACRYLONITRILE
EPA 624, VOLITILE ORGANICS
1,2,2-TETRACHL0RETHANE
i,:•DICHLOROETHANE
1,1 D--CHL•OROETHENE
1,2-DICHLOROBENZENE
1,2-RICHLOROETHANZ
1,2-DICHLOROPROPANE
1,3-DICHLOROBENZENE
1,4•0.ICHLOROBENZENE
3-CHLOROETHYLVINYLETHER
BENZENE
BROMODICHLOROMETHANE
BROMOFORM
ANALYSIS
METHOD DATE TIME BY
EPA 350.3 03/23/01 1120 ML
EPA 351,2 03/26/01 1201 CT
EPA 353.2 03/22/01 1225 CT
EPA 365.2 03/26/011 0943 CT
EPA 200,7 03/26/01 1222 CT
EPA 624 03/22/01 0900 TL
EPA 624 03/22/01 0900 TL
EPA 624 03/22/01 0900 A
EPA 624 03/22/01 0900 TL
13PA 624 03/22/01 0900 TL
EPA 624 03/22/02 0900 TL
EPA 624 02/22/01 0900 TL
EPA 624 03/22/01 0900 TL
EPA 624 03/22/01 0900 TL
EPA 624 03/22/01 0900 TL
EPA 624 03/22/01 0900 TL
EPA 624 03/22/01 0900 TL
EPA 624 03/22/01 0900 TL
EPA 624 03/22/01 0900 TL
EPA 624 03/22/01 0900 TL
EPA 624 03/22/01 0900.' TL
'$AMPLE MATRIX. Ww
TIME SAMPLED- 0805
RECEIVED 5Y-- RM
TYPE SAMPLE- 24 hr comp
RESULT UNITS
a 0.1 ppm
7.69 ppm
e .10 ppm
.67 ppm
,177 ppm
c 100 ug/L
r, 200 ug/L
< 2.5 ppb
K 2.6 ppb
< 2.5 ppb
c 2-5 ppb
< 2.5 ppb
c 2.5 ppb
< 2.5 ppb
c 2.5 ppb
a 2.5 ppb
c 2.5 ppb
e 2.5 ppb
c 2.5 ppb

.i—CJr�—GVV I 1 V YV,••.i i . ,�a.ri . . .-u. rw..... .. .. �. r—, — .--
PAR Laboratories, Inc.
AR
2217 Graham Park Drive
s0aAr0�s,
Lwwj
PO Box 411483
Charlotte, NC 28241-1483
NC CsrtR20, 8C con"9003009
www.pacom
Page 2.
CONTINUATION OF DATA FOR SAMPLE NUMBER 29383
ANALYSIS
ANALYSIS
METHOD
VATE
TIME
BY
RESULT
UNITS
BROMOMETHANE
EPA
624
03/22/01
0900
TL
< 2.5
ppb
CARBON TETRACHLORIDE
EM
624
03/22/01
0900
TL
< 2.5
ppb
CHLOROBEN7,ENE
EPA
624
03/22/01
0900
TL
< 2.5
ppb
CHLOROFTHANE
EPA
624
03/22/01
0900
TL
< 2.5
ppb
CHLOROFORM
EPA
624
03/2g/01
0900
TL
6
ppb
C'HLOROMETHANE
EVA
624
03/22/01
0900
TL
< 2_5
ppb
cis••l.2-DICHLOROPROPENE
EPA
624
03/22/01
0900
TL
< 2.5
ppb
DIBROMOC147.AROMETHANE
EPA
624
01/22/01
0900
TL
< 2.5
ppb
b:'I'H':L8EN2ENE
EPA
624
03/22/02
0900
TL
< 2.5
ppb
METHYLENE CHLORIDE
EPA
624
03/22/01
0900
TL
< 2.5
ppb
TETRACHLOROETHENE
EPA
624
03/22/01
0900
TL
< 2.5
ppb
TOLUENE
EPA
624
03/22/01
0900
TL
< 2.5
ppb
trans-1,2-DICHLOROETHENE
EPA
624
03/22/01
0900
TL
< 2.5
ppb
trans-1,3-DICHLOROPR6PENE
EPA
624
03/22/01
0900
TL
< 2.'
ppb
TRICHL0R0PLUOR0METHANE
EPA
624
03/22/01
0900
TL
< 2.S
ppb
VINYL•CPLORIDE
EPA
624
03/22/01
0900
TL
c 2.5
ppb
J.,1,1-TRICHLOROET WE
EPA
624
03/22/61
0900
TL
< 2.5
ppb
1,1,2-TRICHLOROETHANE
EPA
624
03/22/01
0900
TL
< 2.5
ppb
TRICHLOR05THENE
EPA
624
03/22/01
0900
TL
< 2.5
ppb
EPA 625, SEMI-VOLITILES
EPA
625
03/22/01
0800
TL
4-NITROP142NOL
EPA
625
03/22/01
0800
TL
t 10
ppb
PRNTAC LOROPHENOL
EPA
625
03/22/01
0800
TL
< 10
ppb
2,4•DINI.TROPHENOL
EPA
62S
03/22/01
0000
TL
< 10
ppb
41CHLO,RO-3.•METHYPHENOL
EPA
625
03/22/01
0809
TL
< 10
ppb
2,4,6-TRICHLOROPHENOL
EPA
625
03/22/01
0800
TL
< 10
ppb
2,4-•DICHLOROPHENOL
EPA
625
03/22/01
0800
TL
< 30
ppb
2,4-DIMETHYLPHENOL
EPA
625
03/2.2/01
OSi)0
TL
< 10
ppb
PHENOL
EPA
625
03/22/01
0600
TL
< 10
ppb
2-NITROPHENOL
EPA
625
03/22/01
0800
TL
4 10
ppb
2-CHLOROPHENOL
EPA
625
03/22/01
0800
TL
< 10
ppb
N-NZTE050DIMETRYLAMINZ
-EPA
625
03/22/01
0800
TL
< 10
ppb

4—YJ.7—G1'JYJ 1 I r - - 1111•I I Ilan . r -- --- ter-.. —+ --- ... .
PAR Latwretories, Inc.
���
2217 Graham Park Drive
LU48M oR,es.rnrc.
PO Box 411483
Charlotte; NC 28241-1483
NC C®rm20; SC CertmO63001
www.pa a .com
Page
CONT,I6IUATION OF pATA FOR SAMPLE NUMBER 29383
ANALYSIS
ANALYSIS
METHOD
DATE
TIME
BY
RESULT
UNITS
818(2-CHLOROETHYL)STHER
EPA
625
03/22/01
0800
TL
<
10
ppb
N-NITROSODI-n•PROPYIAMINE
SPA
625
03/22/01
0800
TL
e
10
ppb
NITROBENZENE
EPA
625
03/22/01
0800
TL
<
10
ppb
HEXACHLOROSUTADIENE
EPA
625
03/22/01
08.00
TL
<
10
ppb
- 2,4-TRICHLOROSENZWE
EPA
625
03/22/Ol
0800
TL
<
10
ppb
I50PHORONE
EPA
625
03/22/01
0800
TL
<
10
ppb
NAPTHALENE
EPA
625
03/22/01
0800
TL
<
10
ppb
BIS(2-P-)iLpROETHOXY)METHANE
EPA
625
03/22/01
0800
TL
<
10
ppb
HEXACHLOROCYCLOPSNTADIENE
EPA
6.2
03/22/02
0800
TL
a
10
ppb
1..CHI,.ORONAPTHALENE
EPA
6`l5
03/22/01
0800
TL
<
10
ppb
AC8XAPHTHYLENE
EPA
625
03/22/01
0800
TL
<
10
ppb
ACENAPTfiENE
EPA
62S
03/22/01
0800
TL
<
10
ppb
AZOSENZENE.
EPA
625
03/22/01
0800
TL
<
10
ppb
DIME'THYL PHTHALATE
EPA
625
03/22/01
0800
TL
a
10
ppb
4,6 rJINITROTOLUENE
EPA
625
03/22/01
0000
TL
<
10
ppb
FLUORENE
1CPA
625
03/22/0.1
0800
TL
a
10
ppb
4-CHLOROPHENYL PHENYL'BTHER
EPA
625
01/22/01
0800
TL
<
10
ppb
2,4-DIMtR0T0LUENE
EPA
625
03/22/01
0800
TL
<
10
ppb
DIETHYL.PHTHAI.iTE
EPA
625
03/22/01
0800
TL
<
10
ppb
N-NITROSODIPH=LAMINE
EPA
625
03/22/01
0000
TL
c
10
ppb
HEXACHLOROBENZENE
EPA
625
03/22/0.1
0800
TL
<
10
ppb,
4-BROMOPHEN-FL PHENYL EMP
EPA
625
03/22/01
0800
TL
<
10
ppb
PHENATHASM2
EPA
625
03/22/01
0600
TL
c
10
ppb
ANTH-RACENE
SPA
625
63/22/0.1
0800
TL
<
10
ppb
DI-N-BUTYL-PATHAI,ATE
SPA
625
03/22/01
0800
TL
a
10
ppb
FLUORANTHENE
SPA
625
03/22/01
0800
TL
c
10
ppb
PYRENE
EPA
625
03/22/01
0800
TL
<
10
ppb
BENZIDINE
EPA
625
03/22/01
0800
TL
c
10
ppb
BENZYL BUTYL PHTHALATE
EPA
6;5
03/22/01
0800
TL
<
10
ppb
BIS(2-ETHYLHIML)PHTHALATE
SPA
625
03/22/01
0800
TL
<
10
ppb
BENZO (A)ANTHRACENF
EPA
625
03/22/01
0800
TL
a
10
ppb

PAR Laboratories, Inc.
2217 Graham Park Drive
LABORATORIES, LW.
PG Box 411483
Charlotte,, NC 28241-1483
nrC Cert#20 SC Cerf#94003001
www.pa a .com
Page 4
CONTINUATION OF DATA FOR SAMPLE NUMBER 29383
ANA-lYSIS METHOD
CHRYSENE
EPA
625
3,3-DICHLOROBENZIDINE
EPA
625
OI-n-OCTYLPHTHALATE
EPA
62$
SENZO (B)FLUORANTHENE
EPA
625
BENZO W FLUORANTHENE
EPA
625
3ENZO (A) PYREN'E
EPA
625
1NDh:Np. (1, 2, 3, •cd) PYRENE
EPA
625
DIBENZ .(a,h)ANTHRACENE
EPA
625
BF,NZO (g,h,i)PERYLENE
EPA
625
BIS (2CHLOIOISOPROPYL)ETHER
EPA
62S
HEXACHLOROETHANE
EPA
625
1,2-D3CHLOROBENZENE
EPA
625
1,3 DICHLOROBENZENE
EPA
625
1,4 DICHLOROBENZENE
EPA
625
2-METIiYL-4, 6-DINITROPHENOL
EPA
625
POLYCHIbRINATBD BIPHENOLS(PCB)
EPA
625
PLEB-1016
EPA
625
PCB-12211
EPA
625
PCB 1232
EPA
625
PCB-1242
EPA,
625
PCB-1248
EPA
625
PCB-12S4'
EPA
625
PCB-I-260
EPA
625
PEST:'CIDES
EPA
625
ALPHA .5HC
EPA
625
BET& BHC
EPA
625
DELTA BHC
EPA
62S
GAMMA BHC
EPA
625-
HEPTACHLOR
'EPA
625
ALORTN
EPA
625
vEPI'ACHLOR EPDXIDE
EPA
625
ANALYSIS
DATE TIME BY RESULT UNITS
03/22/01 0800 TL
03/22/01 0800 TL
03/22/01,0800 TL
03/22/01'0800 TL
03/22/01 0600 TL
03%22/01 0800 TL
03/22/01 0800 TL
03/22/01 0800 TL
03/22/01 0800 TL
03/22/01 0800 TL
03/22/01 0P00 TL
03/22/01 0800 TL
03/22/'Ol OBOO TL
03/22/01 0800 TL
03/22/01 0800 TL
03/22/01 0800 TL
03/22/01 0800 TL
03/22/01 0800 TL
03/22/01 0800 TL
03/22/01 0800 TL
03/22/01 0800 TL
03/22/01 0800 TL
03/22/01 0800 TL
03/22/01 0800 TL
03/22/01 0800 TL
03/22/01 0800 TL
03/22/01 0800 Tb
03/22/01 0800 TL
03/22/01 0800 TL
03/22/01 0600 TY,
03/22/01 0800 TL
c 10 ppb
c 10 ppb
< 10 ppb
< 10 ppb
c 10 ppb
c 10 ppb
c 10 ppb
10 ppb
t 10 ppb
< 10 ppb
c 10 ppb
* 10 ppb
c 10 ppb
K 10 ppb
c 10 ppb
50 ppb
50 ppb
t 50 ppb
a 50 ppb
C. 50 ppb
100 ppb
4 50 ppb
c 10 ug/L
* 10 ug/L
< 10 ug/L
10 jag/L
< 10 ug/L
< 10 ug/L
c 10 ug/L

4-kJ-5-4VJU'1 IVJ:'JIJAPI rmum rl1K LF1Our%m1urCiCJ 4f1 / rj,4z:3.000J.�1.`l. -
0
PAR Laboratories, Inc.
pA ,i 2217 Graham Park Drive
t4WWOAI urC. PO Box 411483
Charlotte, NO 28241-1483
NO Oe020; X C•ert#99003001
bFw-W.Partabs.com
CObiTI14UATX01q OF DATA F09'SAMPLE NUMBER 29383
ANALYSIS
ANALxSIS
METHOD
DATE
TIME
BY
RESULT
UNITS
ENDOSULFAN I
EPA
625
03/22/01
0800
TL
< 10
ug/L
4,4 DDE
EPA
625
' 03/22/01
0800
TL
c 10
uq/L
DIELDRIN
EPA
625
03/22/01
0800
TL
e 10
ug/L
ENDRIN•
EPA
625
03/22/01
0800
TL
-i 10
ugA,
4,4 VJ n
EPA
62S
03/22/01
0800
T4
. 10
ug/L
ENDOSULFAN 11
'EPA
625
03/22/01
0800
TL
a 10
ug/L
BNDRiN ALDEHYDE
F,PA
625
03/.22/01
0800
TL
a 10
ug/L
4,4,DDT.
EPA
625
03/22/01
0800
TL
< 10
ug/L
ENDOSULPAN SULFATE
EPA
625
03/22/01
08D0
TL
4 10
ug/L
LABORATORY DIRECTOR

PHARR YARNS INDUSTRIAL WWTP
NPDES PERMIT NO. NC0004812
SLUDGE MANAGEMENT FLAN
The, Pharr Yarns WWTP is currently pilot testing composting the solids produced
during, the treatment process. The composting process being tested is the aerated
stack pile method. If we are unable to obtain optimal results to obtain Class A
bio-solids Pharr Yarns will apply to the Gaston County landfill to dispose of our
sludge there.

Catawba Permitting
Subject: Catawba Permitting
Date: Fri, 24 Mar 2000 13:01:34 -0500
From: Tom Belnick <[e-mail]>
To: Charles Weaver <[e-mail]>,
Dave Goodrich <[e-mail]>
CC: Tom Belnick <1'[e-mail]>
Before you start assigning Catawba files to folks, there are some facilities that may require additional
background info noted below. I'll put a copy of this email into those files, to tip off permit writer about
issues to address.
Color Dischargers- Currently 8 facilities in Color Alliance, plus Newton which did not join. There
will be some language to add in cover letter and possibly permit for these facilities regarding color
study. Charles- I'll give you a hardcopy list of these facilities, and I'm o.k. if you assign them to me.
Valdese WWTP- At the ESB meeting this week on Lakes James/ Rhodhiss"ckory, there was
concern about the increasing TP loading from this facility. Although the load does not appear to
impact Lake Rhodhiss, we don't know how much will be exported downstream to Lake Hickory,
since Rhodhiss doesn't appear to be a TP sink. No need for limits, but Coleen thought we should put
something in permit cover letter asking them to evaluate why TP load is increasing; indicate that
there is concern about downstream lake; and possibly have them do TP optimization study. Michele
W. is looking into how much TP is exported from Lake Rhodhiss to Lake Hickory. Forest W. will
have Jim Reid discuss TP situation with facility.
Mailto:[e-mail]
N.0 DENR-DWQ/NPDES Unit
1617 Mail Service Center, Raleigh NC 27699-1617
Work: [phone] ext. 543
Fax: [phone]
1 of 1 _ 3/24/00 1:01 PM

+ Ne(A,,4V
PROPOSED SAMPLING PLAN FOR
SOUTH FORK CATAWBA RIVER COLOR STUDY
Background
The South Fork Catawba River Water Quality Alliance Inc. (Alliance) has initiated a program
to evaluate the discharge of color and the effect of the color discharges on the South Fork
Catawba River (South Fork). The objectives of this program are:
To provide a high quality database on South Fork color; and
To determine if there is a color problem in the South Fork, and if so, if it is related to
any of the Alliance discharges.
There are eight (8) dischargers involved in this color study. They are:
Facility Name
NPDES Permit #
Receiving Water
Delta Mills WWTP
NC0006190
Clark Creek
Lincolnton-S. Fork WWTP
NC0025496
S. Fork Catawba River
Cherryville WWTP
NC0044440
Indian Creek
Hickory -Henry Fork WWTP
NC0040797
Henry Fork
Gastonia -Long Cr WWTP
NC0020184
S. Fork Catawba River
Yorkshire Americas WWTP
NC0005274
S. Fork Catawba River
Cramerton WWTP
NC0006033
S. Fork Catawba River
Stowe Pharr Yarns WWTP
NC0004812
S. Fork Catawba River
This study will provide a long-term data baseline from which to evaluate the color in the river.
A detailed sampling protocol and quality control program will be implemented in conjunction
with this program to ensure representative data. The color monitoring procedures for this
program will utilize the procedures recommended by the North Carolina Department of
Environment and Natural Resources (NCDENR) and laboratories certified by the State of
North Carolina to conduct these analyses. This report presents the proposed plan for the
conduct of this study.
Monitoring
To develop the required data a detailed monitoring plan is proposed. Monitoring will include
effluent and river samples for ADMI color, pH and temperature. The river samples will
include upstream and downstream samples of all Alliance discharges, samples at NCDENR
monitoring locations, and samples from selected river locations. All river samples will be
monitored for turbidity. Pictures will be taken of the river at the point of the discharge in

PHARR YARNS, INC. WWTP
TOTAL NITROGEN LEVELS JAN. 1998 - DEC. 2000
MONTH
LIMIT
AVERAGE
MAXIMUM
MINIMUM
Jan-98
6.0
7.16
12.34
4.37
Feb-98
6.0
19.89
28.57
3.66
Mar-98
6.0
14.04
18.72
8.26
A r-98
6.0
18.70
31.85
8.79
Ma -98
6.0
10.20
14.94
7.00
Jun-98
6.0
28.13
37.17
19.49
Jul-98
6.0
30.69
45.58
17.97
Au -98
6.0
12.54
15.49
9.32
Se -98
6.0
14.00
16.32
12.39
Oct-98
6.0
12.51
21.07
5.26
Nov-98
6.0
4.48
7.09
2.04
Dec-98
6.0
6.29
8.75
4.73
Jan-99
6.0
5.10
7.10
3.22
Feb-99
6.0
4.40
5.41
3.21
Mar-99
6.0
4.21
5.48
2.74
A r-99
6.0
14.96
21.02
12.15
Ma -99
6.0
18.27
19.69
17.37
Jun-99
6.0
22.71
33.47
13.10
Jul-99
6.0
15.86
20.38
11.45
Au -99
6.0
14.81
19.70
5.54
Se -99
6.0
7.90
10.60
6.10
Oct-99
6.0
14.31
16.93
11.10
Nov-99
6.0
7.02
8.82
5.81
Dec-99
6.0
7.76
8.30
6.97
Jan-00
6.0
11.10
14.65
7.49
Feb-00
6.0
13.46
19.44
8.09
Mar-00
6.0
5.58
7.17
4.83
A r-00
6.0
12.18
15.72
4.87
Ma -00
&0
26.57
30.09
22.74
Jun-00
6.0
15.02
21.32
5.40
Jul-00
6.0
17.88
21.68
14.73
Au -00
6.0
13.26
15.89
8.69
Se -00
6.0
16.53
18.00
14.49
Oct-00
6.0
16.55
17.51
16.14
Nov-00
6.0
18.95
32.90
11.70
Dec-00
6.0
28.17
29.70
26.00

TOTAL NITROGEN PHARR YARNS WWTP
35
30
25
❑AVERAGE
15
10
��� �o �0 c � 0 G�0 0 �C �c°' c lq �°' -
DATE
C �oP moo° moo° 6) �61 o°
�O �� PQ )J P O Oz Qe PQ �° Po Op Oe Fe PQ �J P� O� Oec
DATE

TOTAL PHOSPHOROUS LEVELS
JAN. 98 THRU DEC. 00
IN PPM
MONTH
LIMIT
AVERAGE
HIGH
LOW
Jan-98
1.00
3.1
5.28
0.86
Feb-98
1.00
Mar-98
1.00
2.11
4.25
0.69
A r-98
1.00
3.07
4.59
2.05
Ma -98
1.00
6.03
6.59
5.22
Jun-98
1.00
7.62
12.46
4.74
Jul-98
1.00
5.20
8.19
3.13
Au -98
1.00
7.10
13.12
2.06
Se -98
1.00
1.70
4.50
0.20
Oct-98
1.00
0.24
0.31
0.20
Nov-98
1.00
0.75
0.99
0.48
Dec-98
1.00
1.52
2.24
0.94
Jan-99
1.00
1.40
2.59
0.75
Feb-9 9
1.00
1.16
1.81
0.64
Mar-99
1.00
0.46
1.17
0.2
A r-99
1.00
1.72
2.53
0.89
Ma -99
1.00
0.7
1.02
0.38
Jun-99
1.00
0.98
1.17
0.85
Jul-99
1.00
2.97
6.05
0.2
Au -99
1.00
0.88
1.96
0.2
Se -99
1.00
1.39
1.65
1.08
Oct-99
1.00
2.39
7.68
0.20
Nov-99
1.00
0.98
1.45
0.20
Dec-99
1.00
1.74
3.00
0.71
Jan-00
1.00
2.89
4.59
0.55
Feb-00
1.00
2.08
3.82
1.09
Mar-00
1.00
1.19
2.69
0.46
A r-00
1.00
1.14
1.33
0.81
Ma -00
1.00
2.6
2.97
0.93
Jun-00
1.00
1.43
2.08
0.79
Jul-00
1.00
3.12
3.59
2.19
Au -00
1.00
1.88
4.24
0.53
Se -00
1.00
1.19
1.70
0.71
Oct-00
1.00
1.00
2.02
0.27
Nov-00
1.00
1.03
2.11
0.30
Dec-00
1.00
1.74
1.40
0.32

TOTAL PHOSPHORUS PHARR YARNS WWTP
m
a
Valle]
m
5.00
■ LIMIT
❑ AVERAGE
4.00
3.00
2.00
1.00
mo
,ac -s 41 log sac 10 1 a0 S; (e< 1 �0 ,ac 10 �a1 �� ypq
DATE

MAKE-UP OF PHARR YARNS
WASTEWATER FLOW BY PERCENT
COMPLEX46
UNIT-23
1-85 DIVISION
SPACE DYE
DATE
DOMESTIC
DOMESTIC
DOMESTIC
INDUSTRIAL
Oct-99
42.90%
41.20%
5.10% .
10.800/9
Nov-99
43.80%
27.50%
6.60%
22.10%
Dec-99
40.00%
30.00%
6.60%
23.40%
Jan-00
49.80%
16.40%
5.00%
28.80%
Feb-00
53.00%
30.00%
6.00%
11.00%
Mar-00
62.10%
17.30%
7.20%
13.40%
A r-00
74.00%
1.20%
8.00%
16.80%
Ma -00
81.80%
8.60%
7.70%
1.90%
Jun-00
75.00%
8.00%
5.00%
12.00%
Jul-00
60.00%
23.00%
5.00%
12.00%
Au -00
26.60%
23.20%
5.60%
44.60%
Se -00
27.90%
9.80%
2.00%
60.30%
Oct-00
43.00%
18.90%
2.50%
35.60%
Nov-00
39.50%
14.20%
2.50%
43.80%
Dec-00
54.00%
9.50%
3.10%
33.40%
Jan.-01
49.00%
9.00%
2.00%
40.00%
Feb.-01
39.00%
9.00%
2.00%
50.000/o'
TOTAL DOMESTIC: 73.00%
TOTAL INDUSTRIAL: 27.00%

PHARR YARNS WWTP
EFF.
FLOW JAN.98 - DEC. 00
DATE
AVG.
MAX.
MIN.
PROP. LIMIT
MGD
MGD
MGD
MGD
Jan-98
0.070
0.145
0.015
0.500
Feb-98
0.065
0.130
0:014
0.500
Mar-98
0.060
0.120
0.007
0.500
A r-98
0.049
0.141
0.002
0.500
Ma -98
0.045
0.100
0.009
0.500
Jun-98
0.046
0.100
0.009
0.500
Jul-98
0.047
0.111
0.010
0.500
Au -98
0.048
0.090
0.005
0.500
Se -98
0.055
0.140
0.006
0.500
Oct-98
0.086
0.147
0.018
0.500
Nov-98
0.099
0.168
0.019
0.500
Dec-98
0:097
0.250
0.000
0.500
Jan-99
0.098
0.154
0.043
0.500
Feb-99
0.088
0.153
0.03
0:500
Mar-99
0.086
0.151
0.023
0.500
A r-99
0.071
0.175
0.017
0.500
Ma -99
0.081
0.180
0.017
0.500
Jun-99
0.080
0.178
0.042
0.500
Jul-99
0.056
0.134
0.000
0.500
Au -99
0.144
0.420
0.042
0.500
Se -99
0.088
0.149
0.019
0.500
Oct-99
0.094
0.153
0.028
0.500
Nov-99
0.075
0.229
0.026
0.500
Dec-99
0.080
0.162
0.000
0,500
Jan-00
1 0.086
0.165
0.000
0.500
Feb-00
0.079
0.143
0.032
0.500
Mar-00
0.058
0.125
0.012
0.500
A r-00
0.054
0.199
0.014
0.500
Ma -00
0.055
0.093
0.011
0.500
Jun-00
0.092
0.121
0.041
0.500
Jul-00
0.059
0.140
0.000
0.500
Au -00
0.055
0.093
0.011
0.500
Se -00
0.106
0.203
0.023
0.500
Oct-00
0.097
0.175
0.031
0.500
Nov-00
0.099
0.237
0.032
0.500
Dec-00
0.074
0.180
0.052
0.500

PHARR YARNS EFFLUENT FLOW
N.
w
0.4
0
0.3
O
J
LL
RK
0.1
A� 0 0 9 edCP °9' A§l laco0 00�a1 0 )00 00 0p
OP 41,
DATE
—AVERAGE
—MAXIMUM
MINIMUM
—PROPOSED LIMIT

7325 Watercrest Road
blortCarolina 28210
dr' [(4, gOOO I_ .
Mr. Dave Goodrich- DWQ
NPDES Permit Section
North Carolina Department of Environment and Natural Resources
1617 Mail Service Center
Raleigh, North Carolina 27699-1617
Dear Mr. Goodrich:
As you know, I am the Technical Review Chairman of the Lake Wylie Covekeepers section of
the Catawba Riverkeeper organization. We would like to formally comment during the
upcoming NPDES permit renewal process for the following dischargers:
Discharger
Permit No.
Current Permit
Expiration
Gastonia WWTP- Long Creek
NCO020184
1/31/2000
Newton WWTP
NCO036196
7/31/2000
Hickory -Henry WWTP
NCO040797
7/31/2000
Lincolnton WWTP
NCO025496
7/31/2000
Cherryville WWTP
NCO044440
7/31/2000
Stanley WWTP
NCO020036
7/31/2000
Maiden WWTP
NCO039594
7/31/2000
Delta Mills Maiden WWTP
NC0006190
7/31/2000
Lowell WWTP
NCO025861
9/30/2001
Collins and Aikman d/b/a
Cramerton Auto Products, L.P.
NC0006033
9/30/2001
Pharr Yarns WWTP I
W00048 iW:
9/30/2001
Consistent with FOI Act requirements, we will be contacting the NCDENR regional office at
Mooresville to request dischargers' application documents, draft permits and background
materials. Please notify me as soon public comment hearings are scheduled.
We also wish to continue our ongoing commentary and involvement with the permit renewal
process around the following dischargers:
Crompton and Knowles Permit NC0005274 Permit expired 5/31/1996
Clariant Corporation Permit NC0004376 Permit expired 8/31/1996
Thank you for your continuing cooperation and attention to our requests.
Michael
cc: Donna Lisenby, Catawba Riverkeeper®
Michael Parker, NCDENR Mooresville Regional Office

PhamRalomar Pharr Yarns, Inc.
Pharr International, Inc. P.O. Box 1939
Sylvania Yarn Systems, Inc. 100 Main Street
Mchdenville, N( 28101.1939
Telephone: [phone]
Facsimile: 704/824-0072
October 28, 1999
NC Div. of Water Quality
Water Quality Section/Tech. Support Branch
Ashely House
1618 Mail Service Center
PHARR Raleigh, NC 27699-1618
YARN
S
Subject:: Pharr Yarns WWTP Permit No. NC0004812
Nutrient Study - Gaston County
Dear Mr. Howard:
�D
NU ?_ 1999
DIV. OF WATER QUALITY
DIRECTOR'S OFFICE
This letter and attachments are submitted for your review of our subject nutrient
study as required in Part III Section F of the permit. The study investigates the
feasibility of meeting monthly average total phosphorous limits of 1.0 mg/L and
monthly average total nitrogen limits of 6.0 mg/L during summer months.
Influent characteristics changed in October 1998 with the addition of two of our
textile spinning mills to the sewer collection system. The Complex 46 and Plant
23 facilities contribute domestic wastewater at approximately sixty per cent of the
influent flow. Operation of our wastewater treatment plant has been modified to
enhance treatability and efficiency of the process. The reduction in total
suspended solids with the existing addition of aluminum sulfate has resulted in
reduced total phosphorus concentration as shown in the attached bar graph. The
total nitrogen study was conducted during the months of November 1998 through
March of 1999. We achieved less than 6 mg/L monthly average during 4 of the 5
months with 6.29 mg/L in December of 1998. The reduction in TN was
accomplished by allowing the MLSS to go through an anoxic zone by timer
controlled aerators. This process could not be continued during higher
temperature months due to the required aeration needed to maintain dissolved
oxygen and suspended solids.
The attached bar graph and proposal from Aqua- Aerobic Systems describe the
process equipment needed to comply with the 6 mg/L TN limit. However, further
testing will be needed during summer months with the proposed mixers to
determine the TN concentration. The proposal from Aqua Aerobic was based on
1996 conditions and may not be applicable to the lower influent concentrations.
p9297%
NOV - 4 1999
WATER QUALITY
1%"1 SECTION

Page 2
A revised study will be required prior to purchasing the equipment. We believe
that TN concentrations can be significantly reduced with the addition of mixes to
our extended aeration processbut additional operation under actual conditions
are needed to make sure we can comply with the 6 mg/L limit.
Please contact me at 704-823-2310 if further information is needed at this time.
Sincerely,
u
Mike Church
Environmental Engineer
MC:rgs

TOTAL PHOSPHOROUS LEVELS
JAN. 98 THRU SEPT. 99
IN PPM
MONTH AVERAGE HIGH LOW
Jan-98
3.1
5.28
0.86
Feb-98
12-71
34.5$
2.86
Mar-98
2.11
4.25
0.69
Apr-98-
' 3.07
4:59-
2.05
May-98
6.03
6.59
5.22
Jun-98
7.62
12.46
4.74
Jul-98
5.2
8.19
3.13
Aug-98
7A
13.12
2.06
Sep-98
1.7
4.5
0.2
Oct-98
** 0.24
0.31-
0.2
Nov-98
0.75
0.99
0.48
Dec-98
1.52
2.24
0.94
Jan-99
1.4
2.59
0.75
Feb--99-
1.16
1.81-
0.64
Mar-99
0.46
1.17
0.2
Apr-99
1.72
2.53
0.89
May-99
0.7
1.02
0.38
Jun-99 '
0.98
1.17
0.85
J u I-99
2.97
6.05
0.2
Aug-99
0-88
1.96
0.2
Sep-99
1.39
1.65
1.08
NOTE
BEGAN RECEIVING -APPROXIMATELY 100,000-GALLONS
DOMESTIC WASTE WATER FROM 2 OTHER
MILLS

TOTAL PHOSPHOROUS LEVELS
JAN. 98 THRU SEPT. 99
IN PPM
14
12
10
8
6
4
2
000
a
a
■ AVERAGE
■ HIGH
0 LOW
LIMIT

TOTAL NITROGEN LEVELS JAN. 1998 THRU SEPT. 1999 (in mg/1)
MONTH
AVERAGE
MAXIMUM
MINIMUM
JAN,1998
7.16
12.34
4.37
FEB. 1998
19.89
28.57
3.66
MAR. 1998
14.04
18.72
8.26
APR. 1998
187
31.85
8.79
MAY. 1998
10.2
14.94
7
JUN, 1998
28.13
37.17
19.49
JUL. 1998
30.69
45.58
17.97
AUG, 1998
12,54
15.49
9.32
SEPT. 1998
14
16.32
1239
OCT. 1998
12.51
21.07
5.26
NOV. 1998
4.48
7.09
2.04
DEC. 1998
6.29
8.75
4.73
JAN. 1999
5.1
7.1
3.22
FEB. 1959
4.4
5.41
3,21
MAR. 1999
4.21
5.48
2.74
APR. 1999
14.96
21.02
12.15
MAY. 1999
18.27
19.69
17,37
JUN. 1999
22.71
33.47
13.1
JUL. 1999
15.86
20.38
11.45
AUG. 1999
14.81
19.7
5.54
SEPT. 1999
7.9
10.6
6.1

TOTAL NITROGEN
JAN. 1998 THRU SEPT. 1999
■ AVERAGE
■ MAXIMUM
MINIMUM
B LIMIT
v w v v v v o 0%1 C� ON

Pharr Yarns
McAdenville, NC
b'e ive: To size Aqua -Jet aerators and Aqua DD1M mixers for an existing
activated sludge aeration basin treating textile dye and domestic
wastewater,
Design Criteria:
Flow — 0.5 MGD
Existing Aerators — Four (4) — 15 BP Aqua -Jet Aerators
Basin — 75' W x 225' L x 10 SWD
1.2621MG
HRT — 2.5 days @ Des. Q
MLSS — 2500 mg/1
influent.
BOD — 674 mg/l
COD —1400 mg/l
TSS — 70 mg/l
TS — 2500 mg/l
NH3N — 6 mg/l
TOT-N —13 mg/l
TOT-P — 7.1 mg/l
Effluent : ( Following sand filter, current or required )
BOD — 20 mg/l
COD — 400 mg/1
TSS — 20 mg/1
TS — 650 mg/l
NH3 N — 0.28 mg/l
TOT-N — 6.0 ing/l
TOT-P —1.0 mg/l

Project : Pharr Yarns, NC
Date : 05-20-1996 -
Process Engineer : kml
____= Field Oxygen Transfer Rate Determination (FTR) ______
FTR =
Where,
(T-20)
CWTR x [(Cs x Beta) - Cr] x 1.024 x Alpha
CWTR Clean Water Transfer Rate at Standard
Conditions (Lbs. 02/BHP-Hour)
3.0 Lbs. 02/BHP-Hour
T = Temperature of Wastewater at Design
Conditions, Degrees Centigrade
= 20.0 Degrees Centigrade
Cs = Saturation Concentration at Design Temperature
of 20.0 Degrees Centigrade and 600 ft. Elevation
8.89 mg/1
Beta = Saturation Correction Coefficient
= 0.95 (Typical, assumed)
Alpha = 02 Transfer Rate Correction Coefficient
= 0.85 (Typical, assumed)
Cr = Residual Dissolved 02 Conc. to be maintained, mg/l
= 2.0 mg/1
FTR = 1.81 Lbs. 02/BHP-Hour
Therefore,
175 Lbs 02/Hour
HP (02 Demand) _
1.81 Lbs. 02/BHP-Hour
97 BHP
108 NPHP (At 90% Motor Loading)

�cry
av_v
Ct cA C�
N fN N
x
x
C
dot - i. 2- v�k C,-