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HomeMy WebLinkAboutNC0004812_permit issuance_20140711 (2)NPDES DOCUMENT SCANNIMS COVER SHEET NPDES Permit: NC0004812 Document Type: Permit Issuance Wasteload Allocation Authorization to Construct (AtC) Permit Modification Compliance / Enforcement Permit History Date Range: Correspondence Document Date: r� j` ���� TNIS DOCUMENT IS PRINTED ON REUSE PAPER - IOXORE ANY CONTENT ON THE REVERSE SIDE f E 's t 4.• NCDENR North Carolina Department of Environment and Natural Resources Pat McCrory Governor July 11, 2014 Mr. James Davis, Environmental Manager Pharr Yarns, Inc. P.O. Box 1939 McAdenville, North Carolina 28101 Subject: Issuance of NPDES Permit Permit NCO004812 John E. Skvarla, III Secretary Pharr Yarns Industrial WWTP Gaston County Facility Class II Dear Mr. Davis: Division personnel have reviewed and approved your application for a 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 October 15, 2007 (or as subsequently amended). It is the Division's understanding that Pharr Yarns has entered into a contractual agreement with the City of Gastonia to pump all of the nffs wastewater into the City's collection system. This effort is anticipated to be completed during this permit term. Please contact the Division to request permit rescission following connection. The following changes have been incorporated into this renewal: • Limits for BOD, COD, TSS, Sulfide, Phenols, and Total Chromium have been recalculated based on the most recent production data in the permit application. • Proposed federal regulations require electronic submittal of all discharge monitoring reports (DMRs) and specify that, if a state does not establish a system to receive such -submittals, then permittees must submit DMRs electronically to the Environmental Protection Agency (EPA). The Division anticipates that these regulations will be adopted and is beginning implementation. The requirement to begin reporting discharge monitoring data electronically using the NC DWR's Electronic Discharge Monitoring Report (eDMR) internet application has been added to your final NPDES permit. [See Special Condition A. (7.)] For information on eDMR, registering for eDMR and obtaining an eDMR user account, please visit the following web page: , 1617 Mail Service Center, Raleigh, North Carolina 27699-1617 Phone: 919-807-63001 Internet: www.ncwaterquality.org An Equal Opportunity 1 Affirmative Action Employer— Made in part by recycled paper htW: / /12ortal.ncdenr.=/web /wq/admin/bog/il2u/edmr. For information on EPA's proposed NPDES Electronic Reporting Rule, please visit the following web site: http•//www2 epa gov/compliance/proposed-npdes-electronic-reporting-rule. 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. 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 Resources 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 Sergei Chernikov at telephone number (919) 807-6393. Sincerely, CM at4w(, Thomas A. Reeder ekll&ector, Division of Water Resources cc: Central Files NPDES Files Mooresville Regional Office / Water Quality EPA Region IV (e-copy) WSS/Aquatic Toxicology Unit (e-copy) 1617 Mail Service Center, Raleigh, North Carolina 27699-1617 Phone: 919-807-63001 Internet: www.ncwaterquality.org An Equal Opportunity I Atfirma6ve Action Employer— Made in part by recycled paper Permit NC0004812 STATE OF NORTH CAROLINA DEPARTMENT OF ENVIRONMENT AND NATURAL RESOURCES DIVISION OF WATER RESOURCES 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 applicable conditions set forth in Parts I, II, III and IV hereof. This permit shall become effective August 1, 2014. This permit and authorization to discharge shall expire at midnight on January 31, 2019. Signed this day July 11, 2014. mas A. Reeder, Director do'/Division of Water Resources By Authority of the Environmental Management Commission i Page 1 of 9 Permit NC0004812 SUPPLEMENT TO PERMIT COVER SHEET All previous NPDES Permits issued to this facility, whether for operation or discharge are hereby revoked. As of this permit issuance, any previously issued permit bearing this number is no longer effective. Therefore, the exclusive authority to operate and discharge from this facility arises under the permit conditions, requirements; terms, and provisions included herein. 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 ,extended aeration basin, two clarifiers with alum and polymer addition, two return activated sludge pumps, three mixed media pressure filters, two filter pumps, an aerobic digester, sludge thickening tank, dewatering belt press, sludge storage and drying pad, tablet type chlorinator, and dual chlorine contact chamber 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. Page 2 of 9 Permit NC0004812 A. (1.) EFFLUENT LIMITATIONS AND MONITORING REQUIREMENTS 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 monitored7 by the Permittee as specified below: EFFLUENT CHARACTERI:STIG$. -- i yLIMITS ;: MgNITORING.REQUIREMENTS. ,' '.. ;, Monthly Average ;Daily Maximum _ Measurement' Frequency :Sample Type Sample Locatiori1'. Flow 0.5 MGD Continuous Recording Influent or Effluent BOD5, 20c)C 144.4 Ibs/day 243.2 lbs/day Weekly Composite Effluent Total Suspended Solids 227.2 lbs/day 408.7 Ibs/day Weekly Composite Effluent COD 861.6 -lbs/day 1622.6 lbs/day Weekly Composite Effluent Sulfide 1.9lbs/day 3.7lbs/day Weekly Grab Effluent Phenols 0.9lbs/day 1.9 lbs/day Weekly Grab Effluent Total Chromium 0.9 Ibs/day 1.9 lbs/day Weekly Composite 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 Temperature Daily Grab Effluent Temperature Weekly Grab Upstream, Downstream Conductivity Weekly Grab Effluent, Upstream, Downstream' Total Nitrogen (NO2 + NO3 + TKN)3 No Effluent Limitation (mg/L) No Effluent Limitation (lb/month) 13,698 lb/year (annual mass loading) Weekly Composite Effluent Monthly Calculated Effluent Annually (Calculated) Effluent Total Phosphorus3 No Effluent Limitation (mg/L) No Effluent Limitation (lb/month) 1522 lb/year (annual mass loading)) Weekly Composite Effluent Monthly (Calculated) Effluent Annually (Calculated) Effluent Color4 Monthly Composite Effluent Color4 Monthly Grab Upstream, Downstream' Chronic Toxicft 5 Quarterly Composite Effluent Total Residual Chlorines 28 g/L Weekly Grab 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.(5.). 4 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. 5 Chronic toxicity (Ceriodaphnia, P/F test at 0.62%) shall be performed in January, April, July and October. See Part A.(3.) 6 The facility shall report all effluent TRC values reported by a NC certified laboratory including field certified. However, effluent values below 50 µg/L will be treated as zero for compliance purposes. 7 No later than 270 days from the effective date of this permit, begin submitting discharge monitoring reports electronically using NC DWR's eDMR application system. See Special Condition A. (7.). There shall be no discharge of floating solids or visible foam in other than trace amounts. Page 3 of 9 Permit NC0004812 A. (2.) EFFLUENT LIMITATIONS AND MONITORING REQUIREMENTS 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 monitored7 by the Permittee as specified below: CHARACTERISTICS REQUIREMENTS Monthly Average `.. Daily Maximum Measurement, Frequency "Sample . Type Sample Location? Flow 1.0 MGD Continuous Recording Influent or Effluent BOD5, 20oC 235.7lbs/day 380.2 Ibs/da 3/Week Composite Effluent Total Suspended Solids 318.5 Ibs/day 545.7 Ibs/da Composite Effluent COD 1062.5lbs/day 1924.0lbs/day Com osite Effluent Sulfide 1.9lbs/day 3.7lbs/da Grab Effluent Phenols 0.9lbs/day 1.9lbs/da 43Meek Grab Effluent Total Chromium 0.9 Ibs/day 1.9 Ibs/da Composite Effluent Fecal Coliform (geometric mean) 200/100 mL 400/100 mL Grab Effluent, Upstream, Downstream' NH3-N 3/Week Composite Effluent Dissolved Oxygen 3/Week Grab Effluent, Upstream, Downstream' pH2 3/Week Grab Effluent Temperature Daily Grab Effluent Temperature 3/Week Grab Upstream, Downstream Conductivity 3/Week Grab Effluent, Upstream, Downstream' Total Nitrogen (NO2 + NO3 + TKN)3 No Effluent Limitation (mg/L) No Effluent Limitation (lb/month) 27397 lb/year (annual mass loading) Weekly Composite Effluent Monthly (Calculated) Effluent Annually (Calculated) Effluent Total Phosphorus3 No Effluent Limitation (mg/L) No Effluent Limitation (lb/month) 3044 lb/year (annual mass loading) WeeklyComposite Effluent Monthly (Calculated) Effluent Annually (Calculated) Effluent Color4 Monthly Composite Effluents Color4 Monthly Grab Upstream, Downstreams Chronic Toxicit 5 Quarterly Composite Effluent Total Residual Chlorines 28 pg/L 3/Week Grab 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. (5.). 4 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. 5 Chronic toxicity (Ceriodaphnia, P/F test at 1.2%) shall be performed in January, April, July and October. See Part A.(4.) 6 The facility shall report all effluent TRC values reported by a NC certified laboratory including field certified. However, effluent values below 50 µg/L will be treated as zero for compliance purposes. 7 No later than 270 days from the effective date of this permit, begin submitting discharge monitoring reports electronically using NC DWR's eDMR application system. See Special Condition A. (7.). There shall be no discharge of floating solids or visible foam in other than trace amounts. Page 4 of 9 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, quarterly 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 THP313 for the Chronic Value. Additionally, DWR Form AT-3 (original) is to be sent to the following address: Attention: North Carolina Division of Water Resources Water Sciences Section 1621 Mail Service Center Raleigh, North Carolina 27699-1621 Completed Aquatic Toxicity Test Forms shall be filed with the Water Sciences Section no later than 30 days after the end of the reporting period for which the report is made. ti 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 Water Sciences Section 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 Resources indicate potential impacts to the receiving stream, this permit may be re -opened and modified to include alternate monitoring requirements or limits. If` the Permittee monitors any pollutant more frequently then required by this permit, the results of such monitoring shall be included in the calculation & reporting of the data submitted on the"DMR & all AT Forms submitted. 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. Page 5 of 9 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,guarterlmonitoring 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, DWR Form AT-3 (original) is to be sent to the following address: Attention: North Carolina Division of Water Resources Water Sciences Section 1621 Mail Service ,Center Raleigh, North Carolina 27699-1621 Completed Aquatic Toxicity Test Forms shall be filed with the Water Sciences Section 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 Water Sciences Section 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 Resources indicate potential impacts to the receiving stream, this permit may be re -opened and modified to include alternate monitoring requirements or limits. If the Permittee monitors any pollutant more frequently then required by this permit, the results of such monitoring shall be included in the calculation & reporting of the data" submitted on the DMR & all AT Forms submitted. 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. Page 6 of 9 Permit NC0004812 A.(5.) TOTAL NITROGEN AND PHOSPHORUS MONITORING 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) = Y_ (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 I 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 211.0114. 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: A. (7.) ELECTRONIC REPORTING OF DISCHARGE MONITORING REPORTS Proposed federal regulations require electronic submittal of all discharge monitoring reports (DMRs) and specify that, if a state does not establish a system to receive such submittals, then permittees must submit DMRs electronically to the Environmental Protection Agency (EPA). The Division anticipates that these regulations will be adopted and is beginning implementation in late 2013. NOTE: This special condition supplements or supersedes the following sections within Part II of this permit (Standard Conditions for NPDES Permits): • Section B. (11.) Signatory Requirements • Section D. (2.) • Section D. (6.) • Section E. (5.) Reporting Records Retention Monitoring Reports 1. Reporting [Supersedes Section D. (2.) and Section E. (5) (a)1 Beginning no later than 270 days from the effective date of this permit, the permittee shall begin reporting discharge monitoring data electronically using the NC DWR's Electronic Discharge Monitoring Report (eDMR) internet application. Page 7 of 9 Permit NCO004812 Monitoring results obtained during the previous month(s) shall be summarized for each month and submitted electronically using eDMR. The eDMR system allows permitted facilities to enter monitoring data and submit DMRs electronically using the internet. Until such time that the state's eDMR application is compliant with EPA's Cross -Media Electronic Reporting Regulation (CROMERR), permittees will be required to submit all discharge monitoring data to the state electronically using eDMR and will be required to complete the eDMR submission by printing, signing, and submitting one signed original and a copy of the computer printed eDMR to the following address: NC DENR / DWR / Information Processing Unit ATTENTION: Central Files / eDMR 1617 Mail Service Center Raleigh, North Carolina 21699-1617 If a permittee is unable to use the eDMR system due to a demonstrated hardship or due to the facility being physically located in an area where less than 10 percent of the households have broadband access, then a temporary waiver from the NPDES electronic reporting requirements may be granted and discharge monitoring data may be submitted on paper DMR forms (MR 1, 1.1, 2, 3) or alternative forms approved by the Director. Duplicate signed copies shall be submitted to the mailing address above. Requests for temporary waivers from the NPDES electronic reporting requirements must be submitted in writing to the Division for written approval at least sixty (60) days prior to the date the facility would be required under this permit to begin using eDMR. Temporary waivers shall be valid for twelve (12) months and shall thereupon expire. At such time, DMRs shall be submitted electronically to the Division unless the permittee re -applies for and is granted a new temporary waiver by the Division. Information on eDMR and application for a temporary waiver from the NPDES electronic reporting requirements is found on the following web page: http: / /portal.ncdenr.org/web/wq/admin/bog/ipu/edmr Regardless bf the submission method, the first DMR is due on the last day of the month following the issuance of the permit or in the case of a new facility, on the'1last day of the month following the commencement of discharge. 2. Signatory Requirements fSupplements Section B (11) (b) and supersedes Section B (11.) L" All -eDMRs submitted to the permit issuing authority shall be signed by a person described in Part II, Section B. (11.)(a) or by a duly authorized representative of that person as described in Part II, Section B. (11.)(b). A person, and not a position, must be delegated signatory authority for eDMR reporting purposes. For eDMR submissions, the person signing and submitting the DMR must obtain an eDMR user account and login credentials to access the eDMR system. For more information on North Carolina's eDMR system, registering for eDMR and obtaining an eDMR user account, please visit the following web page: . ` http: / /portal.ncdenr.org/­web/wq /admin/ bog/ipu/ edmr Certification. Any person submitting an electronic DMR using the state's eDMR system shall make the following certification [40 CFR 122.22]. NO OTHER STATEMENTS OF CERTIFICATION WILL BE ACCEPTED: "I certify, under penalty of law, that this document and all attachments were prepared under my direction or supervision in accordance with a system designed to assure that qualified personnel Page 8 of 9 Permit NC0004812 properly gather and evaluate the information submitted. Based on my inquiry of the person or persons who manage the system, or those persons directly responsible for gathering the information, the information submitted is, to the best of my knowledge and belief, true, accurate, and complete. lam aware that there are significant penalties for submitting false information, I including the possibility of fines and imprisonment for knowing violations." 3. Records Retention Supplements Section D.(6.11 The permittee shall retain records of all Discharge Monitoring Reports, including eDMR submissions. These records or copies shall be maintained for a period of at least 3 years from the date of the report. This period may be extended by request of the Director at any time [40 CFR 122.411. Page 9 of 9 Its I RI Outfall 001 I 'XIO T IA: Cr Chamerk MIA NC0004812 Pharr Yams Industrial VPWTP Facility Location StateGrid/Ouad: F14SE/MTHolly, NC Latitude: 350 15'40"N Longitude: 81' 04'39"W Receiving Stream: South Fork Catawba River Sub -Basin: 03-08-34 North IF Map not to scale Drainage Basin: Catawba River Basin Stream Class: WS-V Gaston Counf- PUBLIC NOTICE AFFIDAVIT OF INSERTION OF ADVERTISMENT ,lorth Carolina :nvlrcnmental The Gaston Gazette Management :ommisslon/NPDES Jnit 1617 Mail Service Center Weigh, NC 27699-1617 ilotice of Intent to Gastonia, N.C. ssue a NPDES Gaston County Nastewater Permit the North Carolina Envi- onmental Management 'ommisslon pmposes to slue a NPDES The Gaston Gazette does certify that the advertisement for: rvater discharge permitrmit tto o he person(s) listed below. JJriaen comments regard- ngg the proposed permit Nill be accepted until 30 NC0004812; Pharr Yarns, Inc. days after the publish date of this notice. The Director of the NC Division of (DWR) Water Resources (DWR) Measuring 5.94 inches appeared in The Gaston Gazette, a newspaper published in may a public should there be a signih- Gaston County, Gastonia, N.C., in issue(s): cant degree of public inter- est. Please mail comments and/or Information re- quests to DWR at the above address. Interested 03/19/2014. persons may visit the DWR . It 512 N. Salisbury Street, Raleigh, NC to review In- formation on file. Additional information on NPDES permits and this notice found on our mbe to htlDWIDortal. - ing (919) 607-6390. Phan Yarns, Inc. requested re- newal of permit N00004812 for it's W WTP in Gaston County; this fa- cility discharge is treated wastewater to South Fork Catawba River, Catawba River Basin. 1C-March 19, 2014. . Info: text GS546457 to Name of Account: NCDENR/DWQ/NPDES 56654 Order Number: 54546457 Ad Number: 54629452 Sworn to, and subscribed before me this 19 th day of March, 2014. 0", notu.)3 2�� Carla Norris Potter, Notary Public My Commission Expires Sept.14, 2018 5AW ®v . ,J,1zo1YXewekr&( DENR/DWR FACT SHEET FOR NPDES PERMIT DEVELOPMENT NPDES No. NC0004812 Facility Information Applicant/Facility Name: Pharr Yarns, Inc. Applicant Address: P.O. Box 1939, McAdenville, NC 28101 Facility Address: 147 Willow Drive, McAdenville, NC 28101 Permitted'Flow 0.5/1.0 MGD Type of Waste: 27% - Industrial, 73% - Domestic Facility/Permit Status: Class III/Active; Renewal County: Gaston County Miscellaneous Receiving Stream: South Fork Regional Office: MRO Catawba River Stream Classification: WS-V State -Grid / USGS Quad: F14SE/ 303 d Listed? No Permit Writer: Ser ei Chernikov Subbasin: 03-08-36 Date: February 27, 2014 Drainage Area (mi): 636 Summer 7Q10 cfs 12515 M 9 Winter 7Q10 (cfs): 228 30Q2 cfs - 310 Average Flow cfs : 808 IWC (%): 1.2 Lat. 35' 15' 40" N Long. 81' 04' 39" W BACKGROUND Pharr Yarns, Inc. WWTP treats industrial waste created at the McAdenville facility as well as domestic waste from three Pharr Yarns plants (including the McAdenville plant). The domestic waste from the three Pharr Yarns plants constitutes the majority (73%) of the wastestream, the remainder is process wastewater from the yarn dying that occurs at the McAdenville plant. As a discharger to the South Fork Catawba River, the facility is subject to the'nutrient limits and special monitoring requirements pertaining to color in an effort to improve water qualityin that receiving stream. TECHNOLOGY BASED EFFLUENT LIMIT DEVELOPMENT Reasonable measure of actual production for the facility was established based on the EPA policy (15,618 lb/day). BOD5, COD, and TSS are based on effluent guidelines (40 CFR 410.70 Subpart G Stock and Yarn Finishing Subcategory) and have been recalculated to reflect the most current data available (See attached spreadsheet). COD allocation for domestic wastewater component was calculated using the formula 2.2 X BOD. The 2.2 multiplier was established during the permit renewal in 2000 using site - specific factors and Best Professional Judgment. The results of these calculations are slightly different than the limits in the current permit. Since the facility has no plans to expand production in the foreseeable future (per the facility), it is recommended that the new limits be implemented. In August 2013, Pharr yarns entered into a contractual agreement with the City of Gastonia to pump all of the mill's wastewater into the city's collection system. The project is estimated to be completed within 2 years. TOXICITY TESTING Current Requirement: Quarterly Chronic Toxicity @ 0.62%/1.2% JAN, APR, JUL, OCT Recommended Requirement: Quarterly Chronic Toxicity @ 0.62%/1.2% JAN, APR, JUL, OCT. The facility has been consistently passing its WET tests (please see attached). Fact Sheet NPDES NC0004812 Renewal Page I COMPLIANCE SUMMARY DMRs have been reviewed for the period from negative compliance record (please see attached). 02/01/2009 through 02/01/2014. Facility has a very Pharr Yarns has had operator and equipment issues and problems with slug loads (with high BOD) being discharged into the plant's influent. They have changed over to a liquid chlorination system but fecal violations continued. They requested a technical assistance visit, which was performed during the summer of 2009. They have hired an engineering firm to go through the entire plant and discussed making modifications to the plant. MRO has previously met with Pharr Yarns staff to discuss these issues and the numerous limit violations. The facility has an EPA Administrative Order to bring the facility into compliance. The decision to connect to the POTW should alleviate the existing compliance issues. I. INSTREAM MONITORING The facility is required to conduct self -monitoring of the South Fork Catawba River at one location upstream of the discharge and one location downstream of the discharge. The instrearn self -monitoring includes: fecal coliform, temperature, conductivity, color and dissolved oxygen. An analysis of DO, temperature and conductivity showed that the facility have negligible negative impact on the receiving stream. REASONABLE POTENTIAL ANALYSIS Reasonable potential analysis was conducted for Chromium and Phenols at 0.5 MGD and 1.0 MGD (please see attached). Based on RPA, no water quality based limits are recommended. PROPOSED CHANGES • Limits for BOD, COD, TSS, Sulfide, Phenols, and Total Chromium have been recalculated based on the most recent production data in the permit application. • Proposed federal regulations require electronic submittal of all discharge monitoring reports (DMRs) and specifythat, if a state does not establish a system to receive such submittals, then permittees must submit DMRs electronically to the Environmental Protection Agency (EPA). The Division anticipates that these regulations will be adopted and is beginning implementation. The requirement to begin reporting discharge monitoring data electronically using the NC DWR's Electronic Discharge Monitoring Report (eDMR) internet application has been added to the permit. [See Special Condition A. (7.)] STATE CONTACT If you have any questions on any of the above information or on the attached permit, please contact Sergei Chernikov at (9.19) 807-6393 or sergei.chernikov@ncdenr.gov REGIONAL OFFICE COMMENTS Pact Sheet NPDES NC0004912 Renewal Page 2 TEXTILE EFFLUENT LIMITS SPREADSHEET PERMIT NO: PERMIftEE: COUNTY: I94RLII1l4al901i71 NC0004812 PHARR YARNS, INC. GASTON il!111LB1H BASED ON 40CFR410.70 SUBPART G STOCK AND YARN FINISHING SUBCATEGORY PRODUCTION DATA (in Ibs/da ): DAILY MAX. 15618 according to EPA recommendation MONTHLY AVG. 15618 FROM 40CFR 410.70 SUBPART G (all limits in Ibs/1000 Ibs) I614IRA V., I BOD5 6.8 3.1 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 H must be between 6 and 9 at all times LIMITS 1321.3 6f 21:1 1; e 3.7 1.9 Chromium 1.9 must be between 6 and 9 at all times FINAL 5 380.2 235. 1924.0 1062. 545.7 318. e 3.7 1. of 1.9 0. Chromium 1.9 0. must be between 6 and 9 at all times DOMESTIC WASTE IS 73%, ADD ALLOCA I ION FOR THAT POLLUTANT JDAICY11111W BODS 274.0 182.6 TSS 1 271.0 182.6 COD5 602.7318 401.8212 original BOD limits were 390 lb/day (monthly ave) nd 780 lb/day (daily max), so these limits are still rotective of DO TEXTILE EFFLUENT LIMITS SPREADSHEET PERMIT NO: NC0004812 PERMITTEE: PHARR YARNS, INC. COUNTY: GASTON PERMITTED FLOW: 0.5 MGD BASED ON 40CFR410.70 SUBPART G STOCK AND YARN FINISHING SUBCATEGORY PRODUCTION DATA: DAILY MAX. 15618 according to EPA recommendation MONTHLY AVG. 15618 84.6 17.4 e 0.24 II 0.12 Chromium 0.12 must be between 6 and 9 at all times LIMITS POLUITANT DAILY MAX MONTHLY AVERAGE GODS 106.2 53.1 COD 1321.3 660.6 TSS 271.8 135.9 Sulfide 3.7 1.9 Phenol 1.9 0.9 Total Chromium 1.9 0.9 pH must be between 6 and 9 at all times FINAL LIMITS (Ib/day) POLLUTANT 04111011 MONTHLYAVERAGE BOD5 243.2 144.4 COD 1622.6 861.6 TSS 408.7 227.2 Sulfide 3.7 1.9 Phenol 1.9 0.9 Total Chromium 1.9 0.9 DH must be between 6 and 9 at all tlmes DOMESTIC WASTE IS 73%, ADD ALLOCATION FOR THAT LY MAX MONTHLY AVERAGE BOOS 137.0 91.3 TSS 137.0 91.3 COD 301.3659 200.9106 original BOO limits were 390 lb/day (monthly ave) nd 780 lb/day (daily max), so these limits are still rotective of DO Pharr Yarns 2014 Freshwater RPA - 95% Probability/95% Confidence NC0004812 MAXIMUM DATA POINTS = 58 Qw(MGD)= 0.50 WWTP/WTP Class: III IQ10S(cfs)= 101.87 IWC Q IQIOS = 0.76% 7Q10S(cfs)= 125.00 IWC Q7Q10S= 0.62% 7QIOW(cfs)= 228.00 IWCQ 7QIOW= 0.34% 30Q2 (cfs) = 310.00 IWC Q 30Q2 = 0.25 % Avg. Stream Flow, QA (cS) = 808.00 IWC Qa QA = 0.10% Receiving Stream: South Fork Catwba River Stream Class: WS-V Outfall 001 Qw=0.5MGD PARAMETER STANDARDS 8 CRITERIA (2) o! REASONABLE POTENTIAL RESULTS RECOMMENDED ACTION ~ N )E NC WQS / Applied '/: FAV / a ri k De[. Max Pred Allowable Cw Chronic Standard Acute CW Acute: NO WQS Arsenic C 50 FW(7QIOs) ug/L 0 0 N/A _ _ _ Clvonic: 8 064.5 Acute: NO WQS Total Phenolic Compounds NC 300 A(30Q2) ug/L 58 39 201.3 _ no limit— — — — _ Chronic; 120,000.0 retluce monitoring to Quarterly No value > Allowable Cw Acute: 134,473.7 Chromium NC 50 FW(7Q10s) 1022 ugh 58 30 48.9 no limit A- __ _ _----- Chronic: S,OCw ------------------- reduce monitoring to Quarterly No value > Allowable Cw 4812-RPA-2014, rps Page 1 or 1 2/12/2014 REASONABLE POTENTIAL ANALYSIS 7 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 58 IAL 8 Chromium se" IAl V.I. PY" COes" Total Phenolic Compounds PY" .t4.vlmum data ,Maximum aatn -B,PIrtiF' 68 ow-ta. • 58 Date Data BDL-1/2DL Results _ Date Data BDL=1/2DL Results < 8.734 4.36681223 Sid Dev. 34.3330 1 4.803 4.80349345 Std Dev. 7.2828 56,77 56.768559 Mean 27.6954 2 3.057 3.05676856 Mean 5.0858 43.23 43.231441 C.V. 1.2397 3 < 6.114 3.05676856 C.V. 1.4320 28.82 28.8209607 n 58 4 4,367 4.36681223 n 58 31.88 31.8777293 5 12.66 12.6637555 126.6 128.637656 Mult Factor = 1.00 6 8.297 8.29694323 Mult Factor = 1.00 15.72 15.720524 Max. Value 201.3 ug/L 7 2,183 2.18340611 Max. Value 48.9 ug/L 113.5 113.537118 Max. Pred Cw 201.3 ug/L 8 < 13.1 6.55021834 Max. Pred Cw 48.9 ug/L 30.57 30.5676856 9 10,48 10,4803493 17.03 17.0305677 10 0,873 0.87336245 19.65 19.650655 11 < 54,15 27.0742358 < 13A 6.55021834 12 48.91 48.9082969 3.93 3.930131 13 3.93 3.930131 22.71 22.7074236 14 < 11,79 5.89519651 32.75 32.7510917 15 7,424 7.42358079 30.13 30.1310044 16 T424 7.42358079 54.59 54.6851528 17 2.183 2.18340611 9.607 9.6069869 18 < 10.04 5.02183406 103.1 103.056769 19 3,493 3.49344978 < 14,41 7.20524017 20 < 3.493 1.74672489 30,57 30.5676856 21 < 3,493 1.74672489 17.9 17.9039301 22 < 2.62 1.31004367 18.34 18.3406114 23 < 3 493 1.74672489 42,36 42.3580786 24 < 3.057 1.52838428 31 31.0043668 25 < 2.62 1.31004367 14.85 14.8471616 26 < 3,057 1.52838428 19.65 19.650655 27 < 3,93 1.9650665 < 8.734 4.36681223 28 3,493 3.49344978 19.21 19.2139738 29 < 3,493 1.74672489 < 15.72 7.86026201 30 7.424 7.42358079 < 13.1 6.55021834 31 10.48 10.4803493 < 13.1 6.55021834 32 11.35 11.3537118 < 13.1 6.55021834 33 14.41 14.4104803 < 17.47 8.73362445 34 3.93 3.930131 35.81 35,8078603 35 < 5.24 2.62008734 18.34 18,3406114 36 2.62 2.62008734 42,36 42.3580786 37 < 0,873 0.43668122 < 13.97 6.98689956 38 2.62 2.62008734 < 15.72 7.86026201 39 < 5.24 2.62008734 25,76 25.7641921 40 3.493 3.49344978 10.92 10.9170306 41 < 3.057 1.52838428 < 13A 6.55021834 42 < 2.183 1.09170306 15.72 15.720524 43 3.493 3.49344978 < 3,057 1.52838428 44 < 3,493 1.74672489 15.28 15.2838428 45 < 3,057 1.52838428 201.3 201.310044 46 4.367 4.36681223 < 16.16 8.07860262 47 5.677 5.0768559 < 15.72 7.88026201 48 4.367 4,36681223 < 19.21 9.6069869 49 < 2,62 1.31004367 21.83 21.8340611 50 2,62 2.62008734 < 8.734 4.36681223 51 < 4.803 2.40174672 35,37 35.371179 52 3.493 3.49344978 < 13.1 6.55021834 53 4.367 4.36681223 < 13.1 6.55021834 54 < 3.93 1.9650655 19,65 19,650655 55 < 3.93 1.9650655 16.59 16.5938865 56 < 3.057 1.52838428 4978 49,7816594 57 < 3,057 1.52838428 38.43 38.4279476 58 < 4.367 2.18340611 4812-RPA-2014, data -2- 2/12/2014 SOC PRIORITY PROJECT: No To: NPDES Unit Attention: Charles Weaver Date: September 4, 2013 NPDES STAFF REPORT AND RECOMMENDATIONS County: Gaston NPDES Permit No.: NC0004812 PART I - GENERAL INFORMATION Mailing Address Physical Address 1. Facility and address: Pharr Yams WWTP 101 Main Street Post Office Box 1939 147 Willow Drive McAdenville, N.C. 28101 McAdenville, N.C. 28101 2. Date of investigation: N/A 3. Report prepared by: Michael L. Parker, Regional Supervisor 4. Person contacted and telephone number: James Davis, (704) 823-2310. 5. Directions to site: From the jet. 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 W WTP site is on the left side of Dickson Drive after traveling 0.2 mile. 6. Discharge point: 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 7. Receiving stream or affected surface waters: South Fork Catawba River a. b. C. Classification: WS-V River basin and sub basin no.: Catawba 030834 Describe receiving stream features and pertinent downstream uses: Excellent flow in the receiving stream. Downstream 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: 0.50 MGD and 1.0 MGD. C. Actual treatment capacity of current facility (current design capacity): e. Description of existing or substantially constructed WWT facilities: The existing WWT facilities consist of an influent bar screen with pH control (sodium hydroxide) followed by an aeration basin with fixed floating aerators, polymer and alum addition, two (2) clarifiers, defoamer and sodium hypochlorite addition, flow measurement (continuous flow recording device with totalizer), three (3) mixed media pressure filters, a sludge thickening tank, an aerobic sludge digester, a sludge centrifuge, a belt filter press, tablet chlorine disinfection with dual chlorine contact basins, and dechlorination. PART III - OTHER PERTINENT INFORMATION 1. Special monitoring or limitations (including toxicity) requests: None at this time. PART IV - EVALUATION AND RECOMMENDATIONS Pharr Yarns (PY) requests renewal of the subject Permit. There have been no changes to the existing WWT facility or the NPDES permit since the permit was last renewed. In August, Pharr Yarns entered into a contractual agreement with the City of Gastonia (the City) to pump all of the Mill's wastewater into the City's collection system. Officials with Pharr Yarns estimate it will take 18 — 24 months for the design, approval, and construction -of the infrastructure necessary to make this connection complete. Phar Yarns had hoped that they could partner with the Town of McAdenville on this venture, but negotiations broke down between the Mill and the Town, so the Mill chose to move forward alone. Pending receipt and approval of the WLA, it is recommended that the Permit be renewed as requested. h Adsr\dsr 13 \ph arryam. do c e. Description of existing or substantially constructed WWT facilities: The existing WWT facilities consist of an influent bar screen with pH control (sodium hydroxide) followed by an aeration basin with fixed floating aerators, polymer and alum addition, two (2) clarifiers, defoamer and sodium hypochlorite addition, flow measurement (continuous flow recording device with totalizer), three (3) mixed media pressure filters, a sludge thickening tank, an aerobic sludge digester, a sludge centrifuge, a belt filter press, tablet chlorine disinfection with dual chlorine contact basins, and dechlorination. PART III - OTHER PERTINENT INFORMATION Special monitoring or limitations (including toxicity) requests: None at this time. PART IV - EVALUATION AND RECOMMENDATIONS Pharr Yarns (PY) requests renewal of the subject Permit. There have been no changes to the existing WWT facility or the NPDES' permit since the permit was last renewed. In August, Pharr Yarns entered into a contractual agreement with the City of Gastonia (the City) to pump all of the Mill's wastewater into the City's collection system. Officials with Pharr Yarns estimate it will take 18 — 24 months for the design, approval, and construction of the infrastructure necessary to make this connection complete. Phar Yarns had hoped that they could partner with the Town of McAdenville on this venture, but negotiations broke down between the Mill and the Town, so the Mill chose to move forward alone. Pending receipt and approval of the WLA, it is recommended that the Permit be renewed as requested. C—. ater esources kegional Supervisor Date hAdsr\dsr13\pharryam.doc June 25, 2013 Charles Weaver NCDENR DWQ/Point Source Branch 1617 Mail Service Center Raleigh, NC 27699-1617 Re: Pharr Yarns, LLC Renewal of NPDES Permit No. NC0004812 Gaston County, NC Dear Mr. Weaver, We would like to request the renewal of our subject NPDES permit. Please find attached the original and two copies of the application form, description of our sludge management, Wastewater flow characteristics and supplemental documentation. There have been no major changes at our facility since the issuance of the previous permit. If further information is needed please feel free to call me at 704-823-2310 or e-mail at james.davis@pharr yarns.com. fJesL. tfully, Davis Pharr Yarns Environmental Manager RED JUL 0 5 2013 P PHARR YARNS, LLC WWTP NPDES NO. NC0004812 PRESENT STATUS The present operating status is under a two tiered permit. A.(1.) Effluent and Monitoring Requirements -Final with a flow rate of 0.5 mgd monthly average. We do not expect to exceed this flow. If the'flow is exceeded we would be under the A.(2.) requirements with a monthly flow average of 1.0 mgd. Wastewater Treatments Components: • Caustic feed to raw dye influent • 1.0 MG Aeration Basin 65' x 182' x11.3' depth with four 25 hp aerators and two 15 hp mixers. ® Chemical treatment for flocculation with addition of alum and polymer. • Two clarifiers, 41' diameter (100,000 gals.), 35' diameter (72,000 gals.). • Two sludge return pumps, 350 gpm each. • Two filter pumps, 1-350 gpm, 1-700 gpm. ® Three mixed media filters, 8' diameter with backwash pump. • Liquid sodium hypochlorite disinfection feed. • Dual chlorine contact chambers 12'x30'x10' each ® Dechlorination feed with ascorbic acid. • 1.0 MG aerobic digester with three 75 hp fixed aerators. • Land application of digested solids. PRARR YARNS, LLC WWTP° . NPDES NO. NC0004812 FLOW CHARACTERISTICS Pharr Yarns WWTP receives flow from multiple textile facilities. The following is a break down. ® Pharr Yarns Space Dye: 0.100 mgd of dye and finishing of carpet yarns. ® Pharf Yarns I-85: 0.010 mgd sanitary wastewater. 0.010 mgd process water. ® Pharr Yarns C-46: 0.004 mgd heat setting of carpet yarn, 0.030 mgd process water, 0.020 mgd sanitary wastewater. ® Pharr Yarns Extrusion: 0.010 process water, 0.005 sanitary wastewater.