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Home My WebLink AboutNC0004626_Permit (Issuance)_20040728 NPDES DOCYNENT SCANNING COVER SHEET NPDES Permit: NC0004626 Document Type: Cperinit Issuance Wasteload Allocation Authorization to Construct (AtC) Permit Modification Speculative Limits Staff Report lnstream Assessment (67B) Environmental Assessment (EA) Permit History Document Date: July 28, 2004 TIsie d0c1xx3Mexkt pxrixwted 4021L reuse paper-more ariy Qontent oa t1Ye reWeree aide O(� WA]E'A Michael F.Easley,Governor O� QG State of North Carolina William G.Ross,Jr., Secretary F Department of Environment and Natural Resources T Alan W.Klimek,P.E.,Director Division of Water Qualit July 28, 2004 Mr. David Weber PPG Industries Fiber Glass Products, Inc. P.O. Box 949 Lexington, North Carolina 27293 Subject:Issuance of NPDES Permit NCO004626 Lexington Plant Davidson County Dear Mr. Weber: 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). This final permit includes the following changes: • language authorizing the recycle of effluent upon receipt of a non-discharge permit has been removed due to a misunderstanding that was clarified during the public comment period. PPG should feel free to explore options that would recycle internal waste streams as long as all wastewater is finally discharged according to the requirements of the NPDES permit. This permit includes a TRC limit that will take effect on March 1,2006. If you wish to install dechlorination equipment, the Division has promulgated a simplified approval process for such projects. Guidance for approval of dechlorination projects is attached. 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 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 Toya Fields at telephone number (919)733-5083,extension 551.. Si erely, A n W. Klimek, P.E_ cc: Central Files / Winston Salem Regional Office/Water Quality Section NEDES-Unit j Aquatic Toxicology Unit North Carolina Division of Water Quality (919)733-5083 1617 Mait Service Center FAX(919)733-0719 Permit NCO004626 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, PPG Industries Fiber Glass Products, Inc. is hereby authorized to discharge wastewater from a facility located at Lexington Manufacturing Facility New Jersey Church Road Lexington Davidson County to receiving waters designated as North Potts Creek in the Yadkin-Pee Dee River Basin in accordance with effluent limitations, monitoring requirements, and other conditions set forth in Parts I, 11, III, and IV hereof. This permit shall become effective September 1, 2004. This permit and authorization to discharge shall expire at midnight on May 31, 2009. Signed this day July 28, 2004. ORIGINAL SIGNED BY Tom Belnick Alan W. Klimek, P.E., Director Division of Water Quality By Authority of the Environmental Management Commission Permit NCO004626 SUPPLEMENT TO PERMIT COVER SHEET All Previoos NPD&S 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. PPG Industries Fiber Glass Products, Inc. is hereby authorized to: I Continue to operate an existing 0.6 MGD wastewater treatment facility consisting of the following components: • Mechanical bar screen • Comminutor • Equalization basin Chemical mixing tanks . Primary clarifier . Nutrient addition IDual aeration basins Final clarifiers • Sodium hypochlorite with chlorine contact chamber Dual activated carbon adsorption units with pH adjustment . Backwash equalization basin Sludge holding The facility is located at PPG's Lexington manufacturing facility on New Jersey Church Road in Lexington, Davidson County. 2. 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I f f #r�>b_ ie •I f $ A. !Kt l�:T•� �F�3�rl�h�. �.�:. i ��EE��:k�� t1�� - 4 ��',� PPG Industries/ Lexington Facility - NCO004626 Facility #4 •: .';E ' Location USGS Quad Name: Southmont Lat.: 3504418" Receiving Stream: North Potts Creek Long.: 80°19'32" Stream Class: C Subbasin: Yadkin-Pee Dee 03-07-04 North Not t0 SCALE Permit NCO004626 A (1). EFFLUENT LIMITATIONS AND MONITORING REQUIREMENTS During the period beginning on September 1, 2004 and lasting until expiration, the Permittee is authorized to discharge wastewater treatment plant effluent from outfall serial number 001. Such discharges shall be limited and monitored by the Permittee as specified below: EFFLUENT MONITORING REQUIREMENTS CHARACTERISTICS Monthly Daily Maximum Measurement Sample Sample Average Frequency Type Location' Flow 0.6 MGD Continuous 1Zecordin Influent or g Effluent E30D,5 day,20°C 157 pounds/day 314 pounds/day Weekly Composite Effluent (April 1 —October 31) BOD,5 day,20°C 314 pounds/day 630 pounds/day Weekly Composite Effluent (November 1 —March 31) Total Suspended Solids 105 pounds/day 168 pounds/day Weekly Composite Effluent (April 1 —October 31) Total Suspended Solids 146 pounds/day 292 pounds/day Weekly Composite Effluent (November 1 —March 31) NH3-N Weekly Composite Effluent Oil and Crease 30.0 nig/L 60.0 mg/L Monthly Grab Effluent Fecal Coliform 200/100 nil 400/100 nil Weekly Grab Effluent (geometric mean) Total Residual Chlorine' 28.0 deg/I. Weekly Grab Effluent Temperature Weekly Grab Effluent Total Kjeldahi Nitrogen (TKN) Weekly Composite Effluent NO2+NO3 Weekly Composite Effluent Total Phosphorus Weekly Composite Effluent PH >6 and <9 standard units Weekly Grab Effluent Chronic Toxicity2 Quarterly Composite Effluent Notes: 1. TRC limit will take effect March 1, 2006, 2. Chronic Toxicity (Ccriodaphnia) P/F at 48`,- February, May, August, and November;See condition A(2) of the Supplement to Effluent Limitations and Nlonitoring Requirements portion of this permit. There shall be no discharge of floating solids or foam visible in other than trace amounts. Permit NCO004626 SUPPLEMENT TO EFFLUENT LIMITATIONS AND MONITORING REQUIREMENTS SPECIAL CONDITIONS A(2). CHRONIC TOXICITY PASS/FAIL PERMIT LIMIT (Quarterly) The effluent discharge shall at no time exhibit observable inhibition of reproduction or significant mortality to Crriodaphnin drrbin at an effluent concentration of 48`%n. The permit holder shall perform at a minimum, trnrt rterh monitoring using test procedures outlined in the"North Carolina Crriodaphnin Chronic Effluent Bioassay Procedure," Revised February 1998,or subsequent versions or"North Carolina Phase 11 Chronic Whole Effluent Toxicity Test Procedure"(Revised-February 1998)or subsequent versions.The tests will be performed during the nronths of February, May,August and November. 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 11 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 lI 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 Farm (MR-1)for the months in which tests were performed,using the parameter code TCP3B for the pass/fail results and THP313 for the Chronic Value.Additionally,DWQ Form A'f-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'Pest Forms~hall 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'.ill 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. NCDENR/DWQ FACT SHEET FOR NPDES PERMIT DEVELOPMENT PPG Industries Fiber Glass Products, Inc NCO004626 Facility In•#oimation (1.} Facility Name: PPG Industries F .——_._...------—_.__......__....__............................................................................................................. (2.) Permitted Flow (MGD): j 0.6 MGD (6.) County: Davidson (3•) Facility Class: Class III (7.) Regional Office: Winston-Salem (4 ) Pretreatment Program N/A T _.._ (8.) USGS Topo Quad: D17NE, E17NL ......... .................._........-. — m (5.) Permit Status: Renewal (9.) USGS Quad Name: Southmont Stream Characteristics' (1.) Receiving Stream: I North Potts Creek (7.) Drainage Area (miz) 11 5 (2.) Sub-basin: 03-07-04 (8.) Summer 7Q10 (cfs). j 1.0 (3.) Stream Index Number: 12-1 12 (9.)Winter 7Q10(cfs} € 2.2 --------------- ---------- - - --------. ............. __...f..__._....-........................._._...................... (4.) Stream Classification: C (10.)30Q2(cfs): ..................._........._.........._._....--------._.._..._._._..----- --------._._.._._..------- — — ---....---------------._._..-__._.._..........._.._.._._................ (5.)303(d) Status: Not listed (11.)Average Flow (cfs): 11.0 (6.)305(b) Status: N/A (12.) IWC 48 1.0 Proposed Changes Incorporated into Permit Renewal • Add TRC lit-nit effective 18 months from date of final permit. • Change facility from Class IV to Class III on fact sheet (correction occurred during previous permit cycle, but the old fact sheet was in error.) • Change monitoring frequency for BQD, temperature and pH from 3/week to weekly. 2.0 Summary PPG Industries Fiber Glass Products, inc operates a fiberglass fiber manufacturing facility in Lexington, NC. The Lexington plant currently concentrates the bulk of its fiberglass yarn manufacturing on the textile industry as well as the printed circuit board industry. Mamlfacturing begins with glass raw materials including limestone,silica, boron, clay and fluorspar. These raw materials are blended in powder form and added to melt furnaces. The batch-melt furnaces,operating at 2800"F transform the batch into molten glass. The molten glass is then drawn from the furnaces through electrically heated platinum bushings into continuous fibers. These fibers are gathered into strands and either spooled or chopped into specified lengths. Water sprays cool the glass and keep strand contact points clean during the winding process. PPG's Lexington facility discharges through a single permitted outfall,001. This outfall is from the wastewater treatment plant and receives the following kinds of wastewater: Sanitary (American Children's Home) > Process WW ". In-plant sanitary : Non-contact cooling water Boiler feed Sludge dewatering As part of a settlement agreement reached in 1995, instream monitoring is not a current permit requirement. The facility was required to monitor at l0 instream stations once during the NPDES Permit Fact Sleet — 07/08/04 PPG Industries/ Lexington Facility Paae 2 NCO004626 summer of 1995 and once in 1996. Monitored parameters were DO, temperature,conductivity, pl-I, total phosphorus,nitrate, nitrite, ammonia and TKN. The monitoring was completed as required and is not proposed with this renewal. Current effluent limitations for BOD;and TSS appear to be based on water quality protection and not on federal guidelines. Extensive research was conducted during the 1998 renewal to determine if any federal guidelines exist for such a manufacturing operation. Neither textile nor glass guidelines applies to PPG's process. A review of the WLA file indicates that the limits installed in 1983 were based on BPJ. The facility discharges to North Potts Creek. North Potts is tributary to High Rock Lake and is not listed on the State's 303(d) list. The 2003 Yadkin-Pee Dee basin plan includes a Management Strategy and Recommendations for the High Rock Lake Watershed. The plan recommends that existing dischargers receive notification that discharge limits for total phosphorus may be required in the future. The plan also specifically states that DWQ will attempt to conduct a study of North Potts Creek and South Potts Creek during the next basinwide planning cycle to determine the contribution of this watershed to the impairment of High Rock Lake. During this renewal, the facility noted its intent to explore options for recycling treated wastewater as part of a pilot program. They requested that the permit renewal allow the option to either recycle up to 100`, of the treated wastewater, or discharge up to 100%of the treated wastewater as per existing permit limits. Shannon Thornburg, DWQ Non-Discharge Unit, indicated that a permit from non-discharge may be required before any pilot or full-scale operations may begin. NOTE: This language was removed for the final permit. Tile facility intends to investigate the possibility of recycling internal process waste streams. All effluent will be discharged through the oulfall, not land applied or disposed of elsewhere. The facility also requested a performance-based reduction in monitoring frequencies for BOD, TSS,O&G and fecal coliform. Based on the facility's performance and the site-specific nature of their discharge, BOD, temperature, and pH monitoring will be reduced to weekly to better align with other effluent monitoring requirements. 3.0 Compliance Summary DMR Data Review A review of DMR data for 1/01 through 2/04 indicates that the facility is well operated and performs within its permit limits. Average monthly flows are at 50% permitted capacity; maximum monthly average flows are at 64%of the permitted limit. BOD and TSS levels are also well within limits. A surmmary of DMR data for limited parameters is included below in Table 1. Table 1: DMR Data Summa for Limited Parameters Flow ROD TSS Fecal D.O. O&G Date (MGD) (lbs/da ) (Ibslda ) (#/100 mL) (nt L) (m 1) Monthly Avern e 0.299 8.145 4.555 2.714 2.991 2.089 M a x i mu rn 0.385 132.000 12.000 19.000 5.500 9.200 Minimum 0.221 0.000 0.000 0.000 1 2.000 0.000 S NPDES Permit Fact Shect — 07/08/04 PPG industries/ Lexington Facility Pa<oe 3 NCO004626 PPG is also required to monitor for TRC and nutrients. A TRC limit will be added to the permit during this renewal. All other nutrient monitoring will remain unchanged. Tattle 2 summarizes DMR data collected during the review period for monitored parameters. Table 2: DMR Data Sum ma for Monitored Parameters Total Residual Nitrates/ Temp, Chlorine NH3-N TKN TP nitrites COD Date (de C) (m L) (m L) (m L) (m L) (mg/0 (m L) Monthly Averse 21.737 0.043 0.125 4.490 1.180 2.825 72.664 Maximum 28.000 0.300 1.000 9.000 2.078 6.750 135.000 Minimum 15.000 0.000 0.000 2.480 0.000 0.000 42.000 WET"Test Results PPG Industries has passed 16/17 WET tests administered since 1/00. A previous factsheet indicates that prior to 2000,effluent toxicity was a problem at the Lexington facility, however any toxicity issues appear to have been corrected. Correspondence File Reviezv/Compliance History The Lexington facility appears to be well operated. No maintenance or compliance concerns were noted during the 2001-2004 file review. 4.0 Proposed Schedule for Permit Issuance Draft Permit to Public Notice: May 12,2004 Permit Scheduled to Issue: August 1, 2004 5.0 State Contact Information If you have any questions on any of the above information or on the attached permit, please contact Toya Fields at(919) 733-5083,extension 551. Copies of the following are attached to provide further information on the permit development: • Draft permit NPDES Recommendation bv: Signature Da to Regional Office Comments: h p PPG Industries PPG industries Fiber Glass Products,Inc 473 Now Jersey Church Road Post Office Box 949 Lexington,North Carolina 27293 David W.Weber Staff Engineer-Environmental Phone (336)357-3164 Fax (336)357-7171 E-Mail dweber@ppg.com ' J;:?. ..�Y.-NI:Y..N.•,a..wnwf�M.t�-wqi-w.-w W Via Certified Mail Return Receipt Requested ,�{f E� r5 U JUN 1 1 2003 June 10, 2004 L_ Ms. LeToya Fields VELAR • WATER QUAL+7Y PGfNT SOURCE BRANCH NC Department of Environment &Natural Resources Division of Water Quality -�.»�. _, Point Source Branch 1617 Mail Service Center Raleigh,NC 27699-1617 Re: Draft NPDES Permit NCO004626 PPG Industries Fiber Glass Products, Inc. ("PPG") Lexington Plant Davidson County Dear Ms. Fields: PPG received the subject Draft NPDES Permit on May 17, 2004 and offers the following comments. 1. Supplement To Permit Cover Sheet— Item 1 —Gaseous chlorine is no longer used in the chlorine contact chamber due to safety concerns around the handling of chorine gas. A sodium hypochlorite solution is now used as the source of chlorine in the chlorine contact chamber. 2. Supplement To Permit Cover Sheet—Item 3 - Wastewater Recycling—PPG wishes to clarify that any project for the recycling of treated wastewater would only involve reuse of the water within our manufacturing process. Any and all effluent discharged would be released through our NPDES-permitted outfall. PPG has no plans at this time to utilize the treated effluent for lawn irrigation or other beneficial reuse projects that would involve discharge of the wastewater at a location other than our permitted outfall. Therefore, PPG requests the removal of this Item from the Permit with the understanding that, if a beneficial reuse project is desired, the appropriate Non-Discharge permit application will be submitted by PPG to DWQ. We also agreed in our telephone discussion on this matter, that internal recycling projects as described above do not require permitting as long as all wastewater is discharged through PPG's permitted outfall. - 2 - 3. Item A(l)— Effluent Limitations and Monitoring_Requirements—PPG requests that the pH limits be expressed as follows: "The pH shall not be less than 6.0 standard units or greater than 9.0 standard units." The requested language is identical to that in our current NPDES Permit. Thank you for your consideration of the above comments. Please feel free to contact me if you need any additional information or if you have any questions. Sincerely, i David W. Weber Staff Engineer, Environmental written: Comments re- ti -• ardin PPG Industries , Fiber g g:,.khe proposed r permit will be accepted Glass Products lrac,: r (PO.; BDx .949 Lextng until` 30?clays',after,the IrP'• 3 ya.', publish'datej,of-this no- ton,,NC 27293) has ap- , II IC " I•tice AEI"comments re- plied. for renewal of• s"Ceived, pnor .to -that' NPDES + permit- STATEtor'NORtH- t date ,are sconsidered in NC00046H6 'for .,,their t. �CAROLINA."'. the,:final:determinations ' -.;Le&i ton:Faciiity in-Da ENVIRONMENTAL';' f regarding the'-proposed'. vidson Countyy This 41 MANAGEMENT . permit .The director of permitted. facility `ills= ti the NC-Division';of.Wa;., ,Charges' 0,6:?IMGD of c �tOMMISSION/ i ter Quality--ma decide treated iwastewater�;to 1 r 'NPDES LINITt,;4 : to hold„:a . ubl ep meet- North Potts Creek in the r ,, •1617.-MAItr .' t.• ing r for,`the: c, es t- :Yadkin Pee,.' Dee -,River"- SERVICE;.CENTER-"; permit should tfie Divi- :Basin.:'Currently BODF t° RALEIGH,NC";�r_ sion receive `a"'signifi TSSE:and $total residual 27699=161"7 �i . cant:,degree of.`public chlorine.are waterFgual ity�limited. -This dis- } interest .' iY charge may 'affect,. j NO Ft AT ONi� '" tune=allocations in'lthis Copies of the draft per=: 'Q NT �` pport',- portion, of ,the Yadkin-° F''I ENT TO. ing infoi 66tio;su U - ing information- on file; Pee De�River fiaryin 3 fJ_ E A' 4',Frt� used toidetermine cone r } PDE . '�:1 ditions".°present 'in the' Davidson ,Water -Inc,, LTr WASTFy11XATER;,f draft permit are.availa=`; (PO;, Box • 969 "Wei` ' 'PE MI bfe u om,,request, and` come NC-.27374) hasi payriie t;of te:costs`& "applied for renewal of; reproduction' Mail,coin=� NP.DE5f� permit•On',th, -basis of thor= "menu`,andlor. requests l r NC0o84425`for ittsffl I V� -ough-staff,?revieW -and! for information to the; in `�avidsori , Gounto tt ;application'of NC Gen` 'NC ,Division of>iWater l This,'permitted facilito eral-• Statute 143.21;( disehar es filterback-i"Quality "atF'the aboiie" g r_, Public Lawri92 500 'and; addressoTrcall Ms: Va waso�o i'other lawful standards ilery Stephens iat- (919): unnained,rtributaryr and -•-regulations 'the' 733-5083, extension khe Yadkin River int ,°° `North' Carolina EnWon t ,520`'Please;include the iYadkin-Pee .,Dee_ River,!.-mental"_ Management NPDES, it. number Basin.. Currently,,total- residual chlorine is wa., Commission ' proposes (atta[hed) intany, com- ter quality, limited:'Tfiis to issue'a Natiorial,Pol-tii rmunication �?tnterested. zdischar a may affect _ lutant Discharge Elimi persons may also visit 9 nation System (NPDES) the Division of,fWater. future ailof the :in this wastewater •dischar e� Qualit"" at-512'N, 5alis`� %portion of the Yadkin. -permit to,the,,person(s)r bury Street"Raleigh, NC River. listed ' ' ' 'v- effective, '27604-1148,' 'between '� '' '45'da s from the �May 15,-2004.. Y pub: the hou€s of 8:00 a.m. , lish date of this not_ice._ " and 5:00 p.m. to-review. information on file. AFFIDAVIT OF PUBLICATION STATE OF NORTH CAROLINA Lexington,N.C_ 2004 DAVIDSON COUNTY Jpp a �C/ LoryZ3 of THE DISPATCH, a newspaper published in the city of Lexington, County and State aforesaid, being duly sworn, says the foregoing legal of which the attached is a true copy, was published in said newspaper once the day of a w 2004. '7`� Public tiol�.Fee $ S � (Seal)" Sworn 4%.end"Kbscribed before me, this day of 2C0 ,e^N q C �.,,� 1A 4 , �pU My commission expires 8 L1 v NORTH CAROLINA FORSYTH COUNTY AFFIDAVIT OF PUBLICATION Before the undersigned, a Notary Public of said County and State, duly I commissioned, qualified, and authorized by law to administer oaths, personally appeared D.H. Stanfield, who being duly sworn, deposes and says: that he is Controller of the Winston-Salem Journal, engaged in the publishing of a newspaper known as Winston-Salem Journal, published, issued and entered as second class mail in the City of Winston-Salem, in said County and State: that he is authorized to make this affidavit and sworn statement: that the notice or other legal advertisement, a true copy of which is attached hereto, was published in Winston-Salem Journal on the following dates: May 15, 2004 and that the said newspaper in which such notice, paper document, or legal advertisement was published was, at the time of each and every such publication, a newspaper meeting all the requirements and qualifications of Section 1-597 of the General Statues of North Carolina and was a qualified newspaper within the meaning of Section 1-597 of the general statues of North Carolina. ;� x, P1,Hl�cNOTfD> C7 y �F R,. rr„STATE ORNORTN'.MOUNA ` .ENVIRONMENTALMANAGEMENT:COMMIS510NlNPDESLINTT 1617.MAIL SERV[CE CENTER% RALEIGThis 17th dayof May, 2004 IGATl0H FtwrE T,T0f -• x Y� 4•�. ,NOiIFIC��p,,T10N OF[WTErlT70[seal: 67A NPOEs wA5TEWATER PEnmrr :rjj " ; (signature of perso eking affidavit) Onthehas�soflfwrougtesialfievewandapplicalign. NCGeneralSfal ute,143.21;Public law;92-51XI and other,lawful standards and.regula- tions;the North Cardira Erwlirbnrherite!Managemrw$Commosion pro-I poses�to-issue a NationelPollutarit�Disri[arge•Etimnml°nSysUem Sworn to and subscribed before me this 17th day of May 04 fNPDFS)wasDa+raterdisiirargQpermltathaperaon�sJNstedbelrnvel r t festive45 days.harrthepubl�shdateofthsnotice:!>,--, -:P'};r; . Written°ommei regarding the proposed permit wiu be accepted until 3O days after the pubrish date of this notice;All comments received prior i to that date are considered�n khe final determfnatirx s arding khe pro,I po;gtl pinnrut:The O'vect�r,of the'NC Div s on of Water 0 afity_maY.de ode ro hold a pubic mewing for the proposed peft 01, slieiAt3 the O'rvrsion 'fecetve a significant degree of public interests. �• +.E . Notary C Copies of the drafterm pit and other suuppporting irdoenabor gn(de used to determine conditions present in thedraft permit are available upon re- quest and payment of the Costs of(eprodudron.Mail comments ardlor My Commission expires: September 28, 2005 reG� m°rmeilors Staphens'aion 9)733-0W.'e ansion W- address or cau M.s:.ValerSy Staptians'at(91 733-506:5,'edesnsien 520. Please include theNFDE. permrtnr ber(allatched)rnanycommunwca- lion.Interested persons may.also visit the DrvWon of Waw ouaity at I 512 N:Salisbury Street,Raleigh;NC 27604-1148 between#ue hours of 8:00 a.m,and 5,00 p.m.to review information on tile, The Davie County Water;SysMrn(231;Chalfin Street,ModaMlle,NCi 2M26).has applied for rernewal of NPDES permit;NODOBQ12 for Via Sparks Road WTP.'This;lxmi fted tacility discharges fitlar.bacliwash. wastewater to an unmarred tr 6ul:ary to the Yadkin 9a in Cne'Yadkrrn- Poo��'+ on- Doe tl�scharcla may atw River Basin.te. it(future al residualotal ocad°ris in tlxs�"on ar efllhe f 05-, OFFIClALSEAL ad ,heCilyofWlnatoo-Stem(p0 Box2511,wlnston•Salarn;NC271q Notary Public,North Carolina ; hasappIiedtorrenewalofNPDESpermitNC0079821forfheRA,Thom.i COUNTY OF FOASYTH ;�,.( as:WTPfin!,Forsyth,County.'TFiy'perm hied.facility disdt Mar- ! K I M War- COUNTY H NSON backwash vrastewatec to SaterTr Crack in the Yadk"wr.Pee Dee River Ba- ll t sin.C+rrerdly total iesidual',c1dDrine is water.quaity,imited.This ds-1 l c�qe may affect emre allocatim in ttes portion of Salem Creek, My Commission Expires � S Tie ItyofWinston•SalemJPO'6ox2511 Winston-Salem,NC27.102) has applied fgr,renewal:ot PDES permit NC008601VtDr,9*Neilson WTP in Fbrsyth+Coun[y::This;permitted tac.Srty dischargescfdtar;- q`� 'backwash,irsstewater to an unnamed trfbutary,toMuddy Creeks in the w Yadkin-Pee Coo River Bas'en;C6rnerdlq-total residual f hkwi na is waW quality Iirniteo:Ttis discharge may afad future at°cattons rn bus potttdn; of Muddy The City of Winston-Salem(P.Or Box 25t 1,Winston-Salem;NC 271 R2) hae applied for renewal of NPDES permmt NCDO86762 for.the Nordnxesi WTP in Forrss��t�t�Ccuray_=�Thus-=p nfftted famliy,dsduar"� fiter- backwash wasiswalar to an unneMW tributary to the Yadkin Rrver In the Yedtorr Pee:Doo River Bash CurreraM.total,residual chlorine ismater quality fimrad-,This dnsd[aqye may affect Jubse aBaupons m this portion oftheYadkinRiver �: tPPG'fedustiieslFllrer Glans Products,Ire(P:0"Boii 949 taxi NC'27293)'�has.applied.for;reruewal of NPDES permit NCDO04MB for tlieir.Lezingtori Fartifi[y;in Davioson.Cod' •TNs permitted facility die= dwges 0.6 MGD u�Etm�ed wastewater to NoRki Potts Creekin the Yad 1 kir>Pee Dee River Basing r£irr Iy 1300 TSS.and lolai residual cwrve are watar.quaity Iimkod:Tlis disdierge.may affect futwe ato mfions in Iti9 portion of lure YadldrrPee flea RNer,Basm t:; 'y. ky N,,:`P' Davidson water Inc'(PLO=Btiir 969;welcome NC 27374)has applied; tor.rentvat_btiNPDES permit!NCO0B4425*for;its'-wrp. in;Davidson, ,gunty'tTtis pemitto facie d suxuarges filler-backwash wa%taivatar to art unnamed tributary tq She.Yadk6r River yt the Yad16m Pee flea RkW4 Draft Permit reviews (2) Subject: Draft Permit reviews (2) From: John Giorgino <John.giorgino@ncmail.net> Date: Tue, 25 May 2004 1 1 : 1 1 :22 -0400 To: Toya Fields <Toya.Fields@ncmail.net> Hi Toya, I reviewed NCO027600 (Creswell WTP) and:NC000.452.5=( PPG) and have no comments other than what we discussed concerning the monitoring language on the 'Creswell permit . Thank you for forwarding them to us . John Giorgino Environmental Biologist North Carolina Division of Water Quality Aquatic Toxicology Unit Mailing Address : 1621 MSC Raleigh, NC 27699-1621 Office: 919 733-2136 Fax: 919 733-9959 Email : John.Giorgino@ncmail .net Web Page: http : //www. esb. enr. state. nc .us 1 01' 1 5/25/2004 1 1:20 AM NCO004626 Facility: PPG Industries, Lexington Facility Discharge to: North Potts Creek, C Residual Chlorine Ammonia as NH3 (summer) 7010 (CFS) 1 7010 (CFS) 1 DESIGN FLOW (MGD) 0.6 DESIGN FLOW (MGD) 0.6 DESIGN FLOW (CFS) 0.93 DESIGN FLOW (CFS) 0.93 STREAM STD (UG/L) 17.0 STREAM STD (MGIL) 1.0 UPS BACKGROUND LEVEL (UGIL) 0 UPS BACKGROUND LEVEL (MG/L) 0.22 IWC (%) 48.19 IWC (%) 48.19 Allowable Cone. (ug/1) 35.28 Allowable Concentration (mgll) 1.84 CAmmonia as NH3 (winter) 7010 (CFS) 2.2 Fecal Limit 200/100mI DESIGN FLOW (MGD) 0.6 Ratio of 1.1 :1 DESIGN FLOW (CFS) 0.93 STREAM STD (MGIL) 1.8 UPS BACKGROUND LEVEL (MGIL) 0.22 IWC (%) 29.71 Allowable Concentration (mg/1) 5.54 For Minor domestic-type faciliti : Minimum of 2 mgll (summer) NH3-N; 4 mg/1 (winter) NH3-N hl rin : Residual chlorine must be capped at 28 ug/I to protect for acute toxicity effects Whole Effluent Toxicity Testing Self-Monitoring Summary April 15,2004 FACILITY REQUIREMENT YEAR JAN FEB MAR APR MAY JUN JUL AUG SEP OCT NO\' DEC Phillips Pipeline Co.001 24hr LC50 ac monil epis fthd(grab) 2000 >100 - - - - - - - - - - - V NCIg3_'S91l001 Begin:9114001 Frequency A NonCornp 2001 73.9 - - - - - - - - - - - County:Mecklenburg Region:',IRO Subbasin:CTB34 2002 >100 - - - - - - - - - - ['F: VAR Sptd.l 2003 - >100 -- - - - - - - - - - 7QI0:0.0 SN'C{%;too 2004 - - Phillips Pipeline Co.UO2 24hr LC50 ac nlnnit epis fthd(grah) 2000 >100 - - - - - - - - - - - N00032y9L0U2 Begin:91112001 Frequency NonComp 2001 84.4 -- - -- - - - - - - - - Co, ty:Mecklenhurg Regina:MR0 Suhhasin:CTB34 2002 85.7 - - -- - - - - - - - - Pr: VAR Spcdr. 2003 - >100 - - - - - - - - - - 7010:0.0 M,co;IDo 2004 - -- Phillips Ilia 011"Co. 24hr ac p)f li nn:90% V 2000 -- - Pass - - Pass - - Fail Pass - Pass NC[1UU13ShW l Hegin:911l2(1W Frequency A - Ntar nun Sep Dec N'on('omp Single 2001 - - Pass - - Pass - - Pass - - Pass Cnunly:Cra%en Region:WARD Suhhasin:N'F.lJlll 2002 - - Pass - - Pass - - Pass - - Pass PI': 0.10 Special 2003 - - Pass - - Pass - - Pass - - Pass 7QIU:TIDAL IW0%'IOU 2004 - - 1'ilol,11oun lain 11'll"1 P chc]im:3%:iI pf 3,0 NIGD chr lim 5°'� 2000 Pass - - Pass - - pass - - Pass - - NC002664(11U01 Begir.:3fi11995 Frequency Q PoF - Jan Apr Jul Oct NonComp Single 2001 Pass - - Pass - - Pass - - Pass - Cnunty:Surry Region:WSRO Suhhasin:YADU3 2002 Pass Pass - Pass - - Pass - - Fail Pass - _ IT: L. S1.6al 2003 Pass - - NR Pass - pas. - - Pass - - 7Q10:82.2 fN'C(%'2,5 2004 Pass - 1'itW to N'1PfP chr lim:')U"/. 2000 - - Pass - - Pass - - NRIPasS - - Pass NCOD20.354r001 Begin 211R00'_ Frequency Q Mar Jun Sep Dec NonComp Single 2001 - .y Pass -- - Pass - - Pass - - Pass County:Chatham Region:PRO Suhhasin:CI'F(m 2002 - - Pass - - Pass - - Pass - - Pass PF: 0-75 Special 2003 - - Pass - - Pass - - Pass - - Pass 7Q10_U-OIX) IWC(%;100 2004 - - Pass Illy utv lion Pipeline Co.(001) 24 hr LCSO.rc monil epis fthd 2000 - - - - - >100 - - - - - >100 NC003116liW1 Begin:Ill❑003 FrequencyA NanCamp 2001 - - - - - >100 -- - - - - >100 County.Gullfmd Regius:WSRU Subhasim CPFUK 2002 - - - - - >100 - - - - >100 PF: specie] 2003 - - - - - - - - - - - - 7Q10:0.0 IWC(%:NA 2004 - >100 1'I.ml.tiun Pipeline Co.(U0E) 24 hr LC50 ac mouit epis fthd 2000 - - - - - >100 - - - - - -100 NC1K6116IM01 Beginallf-'UO3 Frequency A 'NonComp 2001 - - - - - >lDO - - - - - -WO Couuty:Guilford Region:WSRU Suhhasia:CPPOS 2002 - - - - - >IUD - - - - - >100 PF Special 2003 - >)CC - - - - - - - - - - 7QIO:0.OU IWC(%:NA 2004 - - Pi'G Induwics clfr line:48% 2000 - Pass - - Pass(s) - - Pass - - Pass - N'CO110-16'6,001 Begm:117I7l999-Frequency Q'P;F Feb Slay Aug Nov T NonComp Singly 2001 - Pass - - Pass - - Pass - - Pass - Cuemty: M-1son Regina:WSRO Sutlhnsin:YAD04 2002 - Pass - - Pass - - Pass - - Pass - PF: 0.6 Special 2003 - - - Pass -- -- Pass - - Pass - 7QI0; L0 I11'C(%:48.19 2004 - Fail PPG-ShcEbv-U0l chr li m:33% F 2000 Pass - - Pass - - Pass(s) - - Pass - - N'CIK1Ui6%51001 Begin 5/1/1999 Frequency Q P;F t Jan Apr Jul Act ' NonComp Single 2001 Pass - - Pass - - Pass - Pass - - CupmV'Cleveland Regimr:NIRO Subbasin BRD04 2002 Pass - - Pass - - Pass -- - Pass - - PF: 13 SN6.1 2003 Pass - - Pass - - Pass - - Pass - - 7QTOL 4.0 IIVCm:33 2004 Pass 1'.incetun F1'SV7-I' chr link.7% 2000 - - Pass - - Pass - - Pass - - Pass NUD(126662;001 Begin 91111_00() Frequency Q Mar Jun Sep Dec NenComp Single 2001 - - Pass - - Pass - -- Pass - - Pass Cuunty:Johnsmn Region_PRO Subbasin 11:110G 2002 - - Pass - - Pass - - Pass - - Pass \ PF.D 275 tiN,ial 2003 - - Pass - - Pass - - Pass - - Pass 7Q10:5.50 IWC(%;7.19 2004 - - I'VAINIonarch Inc. chr lint:90%(Grah) 2000 - - N - - N - - N - - N \C1g51361,001 llegin:ElV1996 Frequency Q 1'1F ,far fun Sep Dtc NonComp Single 2001 - - N - - N - - N - - N Cuenly.Mecklrnburg Regius:MRO Subbasin:CTB34 2002 - - N - - N - - N - - N PF_00216 sr-61 2003 - - N - - N - - N - - N 7010;00 IWC(%:100 2004 - - V Pre 2U1111 Data Available LEGEND: PERM-Permit Requirement LHT-Administrative Letter-Target Frequency=Monitoring frequency,Q-Quarterly;M-Mornhly;BM-Bimnnthly;SA-Semiannually;A-Annually;OWD-Only»hen discharging;D-❑isconlinued monitoring requirement Begin=First month required 7Q 10=Receiving stream low Dow criterion(cfs a-quarterly monitoring increases to monthly upon failure or N Months that testing must occur-ex,Jan,Apr,Jul,Oct NonComp-Culaent Compliance Requirement PF=Permined tlow(MGD) IWC%=Instream waste concentrati PJF=P.ssvFail test AC=Acute CHR=Chronic Data Notation:f-Fathead Minnow,'-Ceriodaphnia sp.;my-Mysid shrimp;ChV-Chronic value;P-Mortality of staled percentage at highest concentration:at-Performed by DWQ Aquatic Tox Unit;bt-Bad test Reporting Notation:----Data not required;NR-Not repave Facility Activity Slams.I-Inactive,N-Now ly issued(To construct);II-Active but not discharging;fi-More data available for month in question;- -ORC signature needed 35 Re: Recycle permit Subject: Re: Recycle permit From: Shannon Thornburg <shannon.thornburg@ncmail.net> Date: Fri, 30 Apr 2004 14:58:30 -0400 To: Toya Fields <toya.fields@nemail.net> Toya, We would not issue a permit until the facility had some sort of plan that we could review. I would advise you to tell the facility that a permit from non-discharge may be required BEFORE any pilot or full-scale operation may begin. Check with Susan or Mike T. , as I believe that they have both written NDPES permits with some non-specific "reclaimed water shall be utilized in accordance with the most recent issuance of the appropriate non-discharge permit" language to solve this sort of chicken before the egg situation. I hope that this helps . Let me know if I can be of further assistance . Shannon Toya Fields wrote : Hi Shannon, I 'm drafting a NPDES permit right now and the facility has indicated that they'd like to explore options for recycling the treated wastewater as part of a pilot program. They want their NPDES permit renewal to allow either the option to recycle up to 100% of the treated wastewater or discharge the wastewater as ` allowed under their current NPDES permit . Tom Belnick mentioned that they would need to get a recycle permit in conjunction with the NPDES permit . What do I need to tell them to do? Thanks, Toya I of' 1 5/1 1/2004 10:25 AM o a PPG Industries PPG Industries Fiber Glass Products,Inc 473 New Jersey Church Road Post Office Box 949 Lexington,North Carolina 27293 David W.Weber Staff Engineer-Environmental Phone (336)357-3184 Fax (336)357-7171 E-Mail dweber@ppg.com Via Certified Mail Return Receipt Requested December 19, 2003 Mrs. Valery Stephens DEC 2 2 2003 NC DENR Water Quality Point Source Branch 1617 Mail Service Center Raleigh, NC 27699-1617 Re: Renewal of NPDES Permit NCO004626 PPG Industries Fiber Glass Products, Inc., Lexington, Davidson County, NC Dear Mrs. Stephens: As per your request, we are pleased to enclose an original, signed NPDES Permit Renewal Application package along with two complete copies for the PPG Industries Fiber Glass Products, Inc. facility in Lexington, NC. We are requesting the reissuance of NPDES Permit No. NC0004626. The SIC Code for facility operations is 3229-Pressed and Blown Glass - not elsewhere classified. The wastewater outfall, Outfall 001, is located at latitude 35 degrees, 44 minutes, 20 seconds, by longitude 30 degrees, 19 minutes, 30 seconds with the receiving water being North Potts Creek. There have not been any changes to the facility since the previous permit. However, the plant plans to explore options for recycling of the treated wastewater as part of a pilot program. We are requesting that the renewal of the permit allows either the option to recycle up to 100%of the treated wastewater or to discharge up to 100%of the treated wastewater as per existing permit limits. The recycling program would not increase the volume of treated effluent and would not affect the existing permitted constituents or effluent limits. The authorized representative to sign all documentation relating to the Permit Renewal package is Mr. Brian M. Pollock, Manufacturing Manager. We request that all NPDES Permit issues be directed to David W. Weber, Staff Engineer, Environmental. David Weber is delegated to sign the DMR reports. - 2 - As part of this permit renewal package, we have included: 1. Cover letter; 2. Completed EPA Form 2C; 3. Narrative description of the sludge management plan 4. Request for a performance based monitoring reduction and; 5. Analytical Data. The data presented in Form 2C Section V is based on plant operating data for the period October 2002 to September 2003 and special analysis conducted by Hydro Analytical Laboratories and STL Laboratories. Copies of these data have been provided in the package. Per conversations with NCDENR employees and website information, General Information Form I is not a requirement for this permit renewal and is not submitted as part of this package. We are including a request for Performance-Based Reduction of NPDES Permit Monitoring Frequencies. This includes a statement of parameter-by-parameter compliance history, calculation of parameter average loadings in relation to average limits, and a statement of eligibility for new monitoring frequencies. Please feel free to contact me if you need any additional information or if you have any questions regarding this submittal_ Sincerely, David W. Weber Staff Engineer, Environmental Attachment PA I.D.NummaR copy m Rem o Form ) OUBN, °d2�oabog8. plgra prim or type In the unshaded areas only. 4626 APDIWBI mores 8-3148. FORM U.C.ENVIRONMENTAL PROTECTION AGENCY w �EPA APPLICATION FOR PE IMIT TO DISCHARGE WASTEWATER 1EXISTING MANUFACTURING,COMMERCIAL,MINING AND SILVICULTURAL OPERATIONS WOES Consolidated Permits Prtayram L OUTPALL LOCATION For each outfail,list the latitude and longitude of Its location to the nearest I5 second&and the name of the receiving water. ■.LATITUDE C. LPNGITUDa NVP*UKR D. Rcc EIV ING WATER(name) 1114t) 01M. A.Svc, ..Ott• 1.YeM. h.ffC. 001 35 44 20 30 19 30 North Potts Creek Site Location Map Attached If.FLOWS,SOURCES OF POLLUTION,ANO TRP.ATMENT TECHNOLOGIES A. Attech a line drawing showing the watK flow through the facility, Indksu sources of intake Water,operations contributing wasbvogto to*a aflllaenk and treatment.unite labeled to coreapord m the more detailed descriptions In Itam B. Construct a water balance on the llne drawing by dwo*p rmags flows.batwwee Inukaa.Operstiormv,traEall runtts, and outfails. If a rater balance cannot be determined(ace,for coresin minhrP ecdVI",laceMda a Pictorial des, 'Ptton of the nature--aiswunt of any sources of water and any collection or treatment mesamm 8. For each outsell, prWde a All Operstloru contributing wastewater to the affluent,induding process wartswater,craft to;wastnwEtar, cooling water,and storm water runoff:121 The nearage flow contributed by each operation,and 131 The treaanent reasivad by the weata nw.CprtMua on additional sheets If necessary. 1.OUT- 2.OPERATIONIEI CONTRINUTING FLOW 7.TREATMEHT FALLN .AVERAGE FLOW .LmaTCOOEs FROM (list) e.OPERATION(list) (Include Lnite) a.DaeCRIPTION TAItLE eo-s 001 Fiberglass Manufacturing 0.214 MGD PPG operates a 0.6 MGD IG 2D Boiler Operations 0.022 MGD treatment acx lty P See attached descri t on IL Non-Contact Cooling 0.034 M D IN Plant Sanitar 0.043 MGD 10 4A Amerir:an Children' s Home 0.004 MGD 1T 4C N teA Stormwater 0.093 MGD mex. 1U 5L 2A 5B 2C 5E 5P planning a pilot program to evaluate the feasibili y of recycling tAL U18 ONLY a ar ) EPA Form 3516-2G (8-90) PAGE 1 OF 4 CONIT[NUE ON REVJ a 0.022 MGD 0.022 MGD BOILER FEED AMERICAN CHILDRENS HOME 0,214 MGD PROCESS 0.214 MG0 men WATER 0.004 MGD CITY OF 0.476 MGD 0.313 MGD WASTEWATER 0.313 MGD + STORMWATER LEXINGTON TREATMENT EVAPORATION 0.163 MGD PLANT DISCHARGE STORMWATER 0,093 MGD MAX. 0.197 MGD NON CONTACT 0.034 MGD 1 0.004 MGD RECYCLE OPTION COOLING (THE PLANT IS PLANNING A PILOT PROGRAM TO EVALUATE THE FEASIBILITY OF RECYCLING) SLUDGE 0.043 MGD 0.043 MGD SANITARY FORM 2 C I I.Q FLOW DIAGRAM PPG LEXINGTON, NORTH CAROLINA SCALE NOT TO SCALE APPROVED BY : DRAWN BY: J.K.S. DATE NOVEMBER 2003 DESIGNED BY REVISED Dectmr,er 17. YOG3 3-`.,4:53 p.in. PROJECT NUMBER AE • DRAWING NO. oiowing: _59)9F•UI.GwG 0WG I N 2 59 719 93as-J MONROE RD�CHAARLOTTE. NC 2627 FIGURE 1 Form 2C.II.B Attached Stormwater Calculations PPG Industries Fiber Glass Products Inc. - Lexington, NC Stormwater flow calculated using the Rational Method from the State of North Carolina Erosion and Sediment Control Planning and Design Manual, December 1, 1993. The rational formula is: Q=CiA where: Q= peak rate of runoff C= runoff coefficient i = average intensity of rainfall A= drainage area C = 095 i = 0.15 inches/hour A = 43,425 ftZ to treatment system Q= (0.95)(0.15 inlhr)(1 ft/12 in)(24 hr/day)(43,425 ftz) Q= 12,376 ft3/day Q= 92,573 GPD s Form 2C.II.B.3.a. Attached Description of Wastewater Treatment Process PPG Industries Fiber Glass Products Inc. - Lexington, NC The wastewater is generated from the fiberglass manufacturing operation, the boiler operations, non contact cooling blow down, plant sanitary wastewater and the sanitary wastewater from the American Children's Home. The wastewater is treated in a 0.6 MGD treatment facility. A process flow schematic is attached. The wastewater treatment processes includes screening of the process wastewater and comminutors for the sanitary wastewaters. All wastes are then equalized, chemically treated using lime and ferric chloride and settled in a primary clarifier. The primary clarifier effluent is treated in an activated sludge system followed by a chlorine contact chamber and activated carbon columns. Currently 100% of the treated effluent is discharged to North Potts Creek. The plant is exploring options to recycle the treated wastewater as part of a pilot program. If the pilot program is successful, the plant would have the option to either recycle up to 100% of the treated wastewater or to discharge 100% of the treated effluent as per existing permit limits to North Potts Creek. The primary and secondary sludges are combined in a stabilization decant/thickener followed by alkaline stabilization, and sludge holding tanks. The decant can be returned to the wet well or treated separately in one of the activated sludge aeration basins. The stabilized sludge is land applied. CHEMICAL CHLORINE BAR EOUALIZATION ADDITION PRIMARY ACTIVATED SLUDGE SECONDARY ACTIVATED CARBON HYDRASIEVE SCREEN TANKS REACTOR CLARIFICATION AERATION BASINS CLARIFICATION CONTACT COLUMNS TANKS TANK FERRIC CHLORINE r CHI ORINF ar ra ST!C WET NU RiENT ID U_ WELL LIME ADDITION AOOITIOtl ADOIRON PROCESS TO HI,H RDCKK WASTE L RO LAKE BLOWER BLOWER PPG AND AMERICA I RECYCLE DPTIC,: CHILDREN.S HOME (THE PLANT IS PLArthttrlC SANITARY WASTE I A PILOT PROGRAM TO { EVALUATE THE FEASIBILITY COMMINUTOR I J OF RECYCLING) I -- - - - - - - -- - --- - - - - � J LIME I I I- - - - _... _ _. - - .- _ _ - _... _.. � _ r —:I—btT:� STABILIZATION ALKALINE SLUDGE LAND DECANT/THICKENER STABILIZATION HOLDING APPLICATION TANK TANKS FORM 2c 11.8.3.a LEGEND PROCESS FLOW SCHEMATIC PPG INDUSTRIES FIBERGLASS PRODUCTS, INC. WaSTc,y-%Tcp LEXINGTON, NORTH CAROLINA SLUDGE SCALE NOT TO SCALE APPKVEB By: orrArm Br: Jx.S NOVEMBER 2003 IIEWWD 01; RrASED Dms,*v 17,2003 9:]9:SV o m - Nt0xcl NumK11 am Al=r , Pof+^MG rM. tro.:p 25919P0]owc ov,G N 259--19 IC4-J rpy (�Prj 7axra I FIGURE 1 CONTINUED FROM THE FRONT VI1. BIOLOGICAL TOXICITY TESTING GATA Do you have any knowladge or reason to believe that any biologkel tort for, or,itshroniatoxioky hoe been mi&.p"wW p}Vo!*d4dwMft or receiving water in rotation to your discharpe within the last 3 yeen?.. Eves(Identify the test(*)and describe thetrpurpows below) ❑No (lo to$@CHO"VLU) Chronic toxicity is tested quarterly as a NPDES permit requirement using the cerio daphnia dubia reproduction test. 2/19/01 - Pass 5/14/01 - Pass 8/6/01 - Pass 11/12/01 - Pass 2/4/02 - Pass 5/6/02 - Pass 8/12/02 - Pass 11/4/02 - Pass 2/10/03 - Pass 5/19/03 - Pass 8/11/03 - Pass EII.CONTRACT ANALYSIS INFORMATION Were any of the analyses reported in item V performed by a contract laboratory or consulting firm? 12 YES(list the name,oddness.and telephone number of and pollutants ❑No(so to Section IX) analyzed bY.each such laboratory or firm beloui! A.NAME B.ADDREia TELEPHONE LUTANVS �o area code# no. Ist Hydro Analytical 6300 Ramada Dr. 336-766-7846 See Box C-2 Attached Clemmons, NC 27012 Insert STL Tallahassee 2846 Industrial Plaza Drive 850-878-3994 See Tallahassee, FL 32301 Attached Insert IX.CERTIFICATION I terrify under penahy oflaw that this document and all attachments wereprapered undermydirection or supervision in accordance with esystern designed to assure that qualifiedpersonnel properlygether and evaluate the information submitted Based on myinquiry ofthe person orpersons who manage the system or those persons directly responsible forgathering the information.the information submitted is,to the best ofmyknowladge andbelief,true,accurate,and eomplefe. I am aware that there are significant penalties for submitting 141se informatioa including the possibility of fine and imprisonment for knowing violations. . A. NAME S OFFICIAL TITLE(type or print) B.PHONE NO.(area code A no.) Brian M. Pollock, Manufacturing Manager 336-357-8151 C. SIGNA'rU RJy � O.DATE SIGNED / �? PAGE 4 OF 4 EPA Form 3510-2C (8-90) FORM 2C.VIII CONTRACT ANALYSIS INFORMATION Contract Laboratory Pollutants Analyzed Hydra Analytical Biochemical Oxygen Demand Chemical Oxygen Demand Total Suspended Solids Ammonia Total Residual Chlorine Fecal Coliform Nitrate/Nitrite Total Organic Nitrogen Oil & Grease Total Phosphorus Surfactants STL Tallahassee Total Organic Carbon Fluoride Sulfate Sulfide Total Boron Total Iron Total Magnesium Total Molybdenum Total Arsenic Total Cadmium Total Chromium Total Copper Total Lead Total Mercury Total Nickel Total Selenium Total Zinc Total Phenols Phenol Bis (2-ethyl-hexyl) phthalate Di-n-butyl phthalate Isophorone 25949W3 Sludge Management Plan PPG Industries Lexington, North Carolina PPG Industries generates both primary and secondary sludge residuals as part of the industrial wastewater treatment process. The primary sludge results from a lime precipitation process and the secondary sludge is generated in an activated sludge biological treatment plant. A schematic of the sludge management system is presented in Figure 1. The sludge management system consists of a stabilization/decant thickener where the primary and secondary sludge are mixed, stabilized, and concentrated. The decant is returned to the activated sludge aeration basin. The sludge is further treated by alkaline stabilization and is held in 1 mg of stabilized sludge holding tanks. The sludge has been characterized as non- hazardous and does not exhibit any of the characteristics defined in 40 CFR 261.21 - 261.24. The stabilized sludge is then transported and land applied. The land application process is permitted by the North Carolina Department of Environment and Natural Resources under Permit No. WQ0000760. There are 809.7 acres permitted for the land application system. The system is permitted for 1,643 dry tons per year. The actual application for the last two years was 1,094.7 dry tons and 655.67 dry tons. Therefore, there is adequate land available for the sludge produced at the PPG facility. Authorized Representative Certification Brian M. Pollock Manufacturing Manager 336-357-8151 Name & Official Title Phone Number j Signature Date Signed WASTE PRIMARY STABILIZATION SLUDGE DECANT/ THICKENER DECANT TO ACTIVATED low SLUDGE AERATION BASIN WASTE SECONDARY SLUDGE LIME 0 0o D 00 y e'P°000Poo°oo°'c"� 00 LAND APPLICATION ALKALINE SLUDGE STABILIZATION HOLDING TANK TANKS SLUDGE MANAGEMENT SYSTEM PPG INDUSTRIES LEXINGTON, NORTH CAROLINA SCALE AS NOTED I APPROVED BY : DRAWN BY:J.K.S. DATE NOVEMBER 20031 DESIGNED BY : REVISED (•lrrrml.rr Ceti, "Gila `r 1;{�� p,rn' PROJECT NUMBER Asir—• DRAWING NO. N259-19 9305—J MONROE RD. CHARLOTTE. NC 21127 FIGURE 1 Performance-Based Reduced Permit Monitoring Frequency US. EPA guidelines provide for a performance based reduction of NPDES permit monitoring' frequencies. In conjunction with our NPDES Permit Renewal Application Form 2C, PPG Industries Fiber Glass Products Inc. is requesting reductions in the monitoring frequency of several effluent characteristics. The PPG Industries, Lexington, NC facility continues to maintain high standards for wastewater treatment and takes pride in its excellent historical performance in regard to its NPDES permit compliance. Based on a parameter-by-parameter analysis and two-year composite averages versus our Monthly Average Discharge Limitations we are requesting a reduction in monitoring frequencies per the USEPA's Interim Guidance for Performance-Based Reduction of NPDES Permit Monitoring Frequencies. The two-year time period is from October 2001 to September 2003. The following table lists the parameters of interest, our two-year composite averages for each parameter (based on the attached NPDES Effluent Data Logs in the analytical monitoring section), our Monthly Average Discharge Limits, and the Ratio of PPG's Two-Year Composite Average to the corresponding Monthly Average Discharge Limit. Effluent Characteristics Two-Year NPDES Two-Year Composite Monthly Composite vs. Average Average Monthly Average Discharge Discharge Limit Limitation BOD, 5-Day, 20°C 1.9 lb/day 157 lb/day 1.2% (April 1 - October 31) BOD, 5-Day, 20°C 3.6 lb/day 314 lb/day 1.1% (November 1 - March 31) Total Suspended Solids 2.5 lb/day 105 lb/day 2.4% (April 1 - October 31) Total Suspended Solids 5.6 lb/day 146 lb/day 3.8% (November 1 - March 31) Oil and Grease 1.6 mg/L 30 mglL 5.3% Fecal Coliform 1.1 1 100 ml 200 1 100 ml 0.5% (Geometric Mean) Using the ratio of Two-Year Composite Averages to the Monthly Average Discharge Limits from the table above, and comparing to Table l (Attached) in the Interim Guidance for Performance-Based Reduction of NPDES Permit Monitoring Frequencies, PPG is eligible and is requesting the following reductions in monitoring frequency: Effluent Characteristics Current Monitoring Eligible Monitoring Frequency Frequency BOD, 5-Day, 200C 31 Week 1/ Week (April 1 - October 31) BOD, 5-Day, 20°C 3/ Week 11 Week (November 1 - March 31) Total Suspended Solids Weekly 1/ 2 Months (April 1 - October 31) Total Suspended Solids Weekly 1/ 2 Months (November 1 - March 31) Oil and Grease Monthly 1/ 6 Months Fecal Coliform Weekly 1/ 2 Months (Geometric Mean) PERFORMANCE-BASED.REDUCTION OF MONITORING FR£QUENClLI include pollutants which pose heightened risks to human or environmental health, such as highly toxic or bioaccumulative compounds. 3) Parameter-by-Parameter Performance History At a minimum, the two most.recent years of monthly average effluent data representative of current operating conditions for-the parameter at the particular outfall will be used to calculate the-long term average discharge rate for use in Table • The baseline monitoring•frequencies in Table 1 of this guidance will normally be considered the level of monitoring in the existing effective NPDES permit. It is important to recognize that permittees that receive"monitoring frequency reductions in accordance with-Table 1 or Table 2 are still expected to take all appropriate measures to control both the average level of pollutants of concern in their discharge (mean) as well as the variability of such parameters in the discharge (variance), regardless of any reductions in monitoring frequencies granted from the baseline levels. Reliance on monitoring the discharge at a reduced frequency as the sole means of tracking and' controlling.the discharge could increase the risk of violations. Table I Ratio of Long Term Effluent Average to Monthly Average Limit Baseline Monitoring 75-667a 65 50% 4 -25% <25% 7/wk 5/wk 4/wk 3/wk 1/wk- 6/wk 4/wk 3/wk 2/wk 1/wk 5/wk 4/wk 3/wk 2/wk 1/wk 4/wk 3/wk 2/wk i/wk 1/wk 3/wk 3/wk 2/wk 1/wk 1/wk 2/wk 2/wk I/wk 2/mo I/mo 1/wk 1/wk I/wk 2/mo 1/2mos 2/month 2/mo 2/mo 2/mo 1/quarter 1/month I/ma I/mo 1/quarter 1/6mos Note: See above eligibility requirements. LyrERiM GUIDANCE APRIL 1996 -5-'