HomeMy WebLinkAboutNC0000639_Permit (Issuance)_20061011NPDES DOCIMENT SCANNING COVER SHEET
NC0000639
Sapona Manufacturing Company
NPDES Permit:
Document Type:
Permit Issuance
Wasteload Allocation
Authorization to Construct (AtC)
Permit Modification
Complete File - Historical
Engineering Alternatives (EAA)
Correspondence
Instream Assessment (67b)
Speculative Limits
Environmental Assessment (EA)
Permit
History
Document Date:
October 11, 2006
This document is printed on reuse paper - ignore any
content on the reYerse side
Michael F. Easley, Governor
William G. Ross Jr., Secretary
North Carolina Department of Environment and Natural Resources
Alan W. Klimek, P.E. Director
Division of Water Quality
October 11, 2006
Mr. Dean F. Lail
Sapona Manufacturing Company, Inc.
2478 Cedar Falls Road
Cedar Falls, North Carolina 27230
Subject: Issuance of NPDES Permit NC0000639
Sapona Manufacturing Company
Randolph County
Dear Mr. Lail:
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 major changes from the draft permit sent to
you on August 30, 2006:
> To support nutrient -sensitive modeling for the Deep River watershed, quarterly nutrient
monitoring has been added to outfall 001. A summary of the Division's nutrient monitoring
strategy is enclosed for your reference.
> A re -opener condition has been added in the event that a different nutrient monitoring
regimen becomes necessary later in the permit cycle.
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 Charles Weaver at telephone number (919) 733-5083, extension 511.
Sincerely,
s
Alan W. Klimek, P.E.
cc: Central Files
Winston-Salem Regional Office/Surface Water Protection
NPDES Unit
No `Carolina
,Naturally
North Carolina Division of Water Quality 1617 Mail Service Center Raleigh, NC 27699-1617 Phone (919) 733-5083 Customer Service
Internet h2o.enr.state.nc.us 512 N. Salisbury St. Raleigh, NC 27604 FAX (919) 733-0719 1-877-623-6748
An Equal Opportunity/Affirmative Action Employer-50% Recycled/10% Post Consumer Paper
Permit NC0000639
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,
Sapona Manufacturing Company, Inc.
is hereby authorized to discharge wastewater from a facility located at
Sapona Manufacturing Company
2478 Cedar Falls
Cedar Falls
Randolph County
to receiving waters designated as the Deep River in the Cape Fear River Basin in accordance with effluent
limitations, monitoring requirements, and other conditions set forth in Parts I, II, III and IV hereof.
This permit shall become effective November 1, 2006.
This permit and authorization to discharge shall expire at midnight on September 30, 2011.
Signed this day October 11, 2006.
cs
Alan W. Klimek, P.E., Director
Division of Water Quality
By Authority of the Environmental Management Commission
Permit NC0000639
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.
Sapona Manufacturing Company, Inc., is hereby authorized to:
1. Continue operation of a 0.01 MGD wastewater treatment facility with the following
components:
❖ Manual bar screen
❖ Aeration basin with diffused aeration from 2 blowers
❖ Clarifier with sludge return
+ Effluent chlorination
This system discharges via outfall 001 from a facility located at 2478 Cedar Falls Road in
Cedar Falls, Randolph County.
2. Continue to discharge boiler blowdown, cooling tower blowdown, and air washer
wastewater via outfall 002.
3. Discharge from said treatment works at the locations specified on the attached map into
the Deep River, classified C waters in the Cape Fear River Basin.
,USGS Quad No.
x1USGS Quad Name
Quad: Ramseur, N.C.
Latitude: 35°44'51"(001);
35°44'50" (002)
Longitude: 79°43'33" (001);
78°43'34" (002)
Stream Class: C Subbasin: 30609
Receiving Stream: Deep River
NC0000639
Sapona Manufacturing
Company
North
SCALE 1:24000
Permit NC0000639
A. (1.) EFFLUENT LIMITATIONS AND MONITORING REQUIREMENTS (001)
During the period beginning on November 1, 2006 and lasting until expiration, the Permittee is authorized to
discharge from outfall 001 (Domestic Waste). Such discharges shall be limited and monitored by the
Permittee as specified below:
PARAMETER :
DISCHARGE
LIMITATIONS ;
MONITORING REQUIREMENTS....
Monthly
Average
-Daily
Maximum
Measurement
Frequency
Sample
° Type
Sample Location
Flow
0.01 MGD
Weekly
Instantaneous
Influent or Effluent
BOD, 5-day, 200C
30.0 mg/L
45.0 mg/L
Weekly
Grab
Effluent
Total Suspended Solids
30.0 mg/L
45.0 mg/L
Weekly
Grab
Effluent
NH3-N
2/Month
Grab
Effluent
Fecal Coliform
(geometric mean)
200 / 100 ml
400 / 100 mi
Weekly
Grab
Effluent
Total Residual Chlorines
_
28 pg/L
2/Week
Grab
Effluent
Temperature
Weekly
Grab
Effluent
Total Nitrogen
(NO2 + NO3 + TKN)
•
Quarterly
Grab
Effluent
Total Phosphorus
Quarterly
Grab
Effluent
pH
> 6.0 and < 9.0 standard units
2/Month
Grab
Effluent
NOTES:
1. The TRC limit takes effect May 1., 2008. Until then, the permittee shall monitor TRC [with no effluent limit].
THERE SHALL BE NO DISCHARGE OF FLOATING SOLIDS OR VISIBLE FOAM IN OTHER THAN TRACE AMOUNTS.
A. (2.) EFFLUENT LIMITATIONS AND MONITORING REQUIREMENTS (002)
During the period beginning on the effective date of the permit and lasting until expiration, the Permittee is
authorized to discharge from outfall 002 (Boiler Blowdown, Cooling Tower Blowdown, Air Wash
Wastewater). Such discharges shall be limited and monitored by the Permittee as specified below:
PARAMETER
DISCHARGE :
LIMITATIONS
MONITORING REQUIREMENTS
Monthly
Average
Dail
Maximum .
Measurement `:
Frequency ':
Sample
Type
Sample
Location
Flow (MGD)
Semi-annually
Estimate
Effluent
Temperature1
Semi-annually
Grab
Effluent
Total Residual Chlorine2
28 pg/L
Semi-annually
Grab
Effluent
pH
! > 6.0 and < 9.0 standard units
1 Semi-annually
Grab
Effluent
NOTES:
1. The temperature of the effluent shall be such as not to cause an increase in the temperature of the receiving waters of
more than 2.8°C and in no case cause the ambient water temperature to exceed 32°C.
2. The TRC limit takes effect May 1., 2008. Until then, the permittee shall monitor TRC [with no effluent limit]. This
monitoring requirement only applies if chlorine is added to the cooling water.
THERE SHALL BE NO DISCHARGE OF FLOATING SOLIDS OR VISIBLE FOAM IN OTHER THAN TRACE AMOUNTS.
Permit NC0000639
. A. (3.) BIOCIDE CONDITION
There shall be no chromium. zinc or copper added to the treatment system except as pre -approved
additives to biocidal compounds.
The permittee shall obtain approval from the Division's Aquatic Toxicology Unit prior to the use of any biocide (not
previously approved by the Division) in the effluent discharged under this permit. Approval for use of any biocide
not previously approved should be requested at least 90 days in advance of any planned usage.
Contact the Aquatic Toxicology Unit for detailed instructions on requesting approval of biocides:
NC DENR / DWQ / Aquatic Toxicology Unit
1621 Mail Service Center
Raleigh, North Carolina 27699-1621
Concentrations of chromium, copper, or zinc added to biocides shall not exceed applicable water quality standards or
action levels in the receiving stream.
A. (4.) PERMIT RE -OPENER: SUPPLEMENTARY MONITORING
The Division may, upon written notification to the Permittee, require additional effluent monitoring that it
deems necessary to support its water quality protection and restoration efforts in the receiving stream.
NORTH CAROLINA
RANDOLPH COUNTY
AFFIDAVIT OF PUBLICATION
Before the undersigned, a Notary Public of said
County and State, duly commissioned, qualified, and
authorized by law to administer oaths, personally
appeared
Maria Shaw
who being first duly sworn, deposes and says, that
he (she) is
Business Manager
Of The Courier -Tribune, engaged in the publication
of a newspaper known as The Courier -Tribune,
published, issued, and entered as second class
mail in the City of Asheboro, in said County and
State; and the he (she) 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 the Courier -
Tribune on the following dates:
September 1, 2006
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 newpaper meeting all of the
requirements and qualifications of Section 1-597 of
the General Statutes of North Carolina, 1943, as
amended, and was a qualified newspaper within the
meaning of Section 1-597 of the General Statutes
of North Carolina.
this 1st day of September, 2006
Sworn to and subscribed before me this 1st
day o•r.September, 2006
Notary Public
My commission expires: 6/19/11
I, -'PUBLIC NOTICE'
STATE ORNoRn'jji CroROUNA;,
:...ENVIRONMENTAL VIIIANAGE=
mENT COMMiSSIONIN PDES
`UNIT 1617 MAiL'SERVICE->
'.17;1 CEintAR ALEIGH NC.'
''27699-1¢1.7 it ,
^ NOTIFlCATION.OPINTENT.
'I TO.ISSUEANPRES,WASTE-':.:1
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;Or! thheb` stof.' hofough`staff'
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;General Stet 2f;.public
Law, 92-5t)d:and:'esther lawful •
istahaii0 9iiid,, egtilatio : the
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Elated beloi eifecttvs 'd5:da)rs;
({gr 't upli p date` of tt s no=
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.date.are:consi the final
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a NC Water O is ty
1•> ;de a to holcta•apublic7:
m« iig -Proposed Pe ►Rft'
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Copies Witte"? t 'permit and
016 othe, ed, 7dgtor !to .Oonditions
p es9R), , t e ,¢ a perSrift.are,
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qu !tor •Una .on -So tfre.lVC-
Division .of Water Quality at the
above: address or call the Paint
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`pang `Incr:(PO' ox'128; Cedar:
Falls; NC.l» ,i ) applied' 1O is
renewal of: ermt NCOd0O639
fora �,r�. s`iio
County. , Is; permtt•facillty`d s. -
chargea`�{eatdd wastewater to:`�
: the Pg.9t ion tho.Cape Fear.:
F1iv�r Basin urfentIy ; eca1 ooti=.
Corm •andtbtal resldualchiortge'
are water. J 'at( tirnited, This .
- ) %/30/oh
SAP O NA
MANUFACTURING COMPANY, INC.
Quality Yarns Since 1836
1/26/06
Ms. Valery Stephens
NC DENR / Water Quality / Point Source Branch
1617 Mail Service Center
Raleigh, NC 27699-1617
Re: Cover Letter for renewal of NPDES Permit NC0000639
Dear Ms. Stephens:
Please renew our permit for wastewater discharge. The application is enclosed.
There have been no significant changes to our system since issuance of the last permit.
Please note that we have contracted with a company to manage our system. The company is Meritech Inc.,
642 Tamco Rd. Reidsville, NC 27320. The ORC is Arnold Allred.
Thank you,
Dean F. Lail
V. President
Sapona Manufacturing Company, Inc.
F �3 1 0 2006
Email: DLail@saponamfg.com Web: www.saponamfg.com
P.O. Box 128 • 2478 Cedar Falls Road • Cedar Falls, NC 27230 • Ph. 336-625-2727 • Fax 336-626-0876
NPDES APPLICATION FOR PERMIT RENEWAL - FORM A
For Publicly Owned Treatment Works (POW) or other treatment systems treating
domestic wastes < 0.1 MGD with no pretreatment program. ,.
Mail the complete application to:
N. C. Department of Environment and Natural Resources
Division of Water Quality / NPDES Unit
1617 Mail Service Center, Raleigh, NC 27699-1617
NPDES Permit
INC0000639
F E B 1 0 2006
If you are completing this form in computer use the TAB key or the up - down arrows to move from one
field to the next To check the boxes, click your mouse on top of the box. Otherwise, please print or type. ----_�
1. Contact Information:
Owner Name
Facility Name
Mailing Address
City
State / Zip Code
Telephone Number
Fax Number
e-mail Address
Sapona Manufacturing Company, Inc.
Sapona Manufacturing Company, Inc.
r0 Box 128
Cedar Falls
North Carolina 27230
(336) 625-2727
(336) 626-0876
lail@aol.com
1. Location of facility producing discharge:
Check here if same address as above EJ
Street Address or State Road 2478 Cedar Falls Road
City
State / Zip Code
County
Cedar Falls
North Caret i na 27230
Randolph
1. Operator Information:
Name of the firm, public organization or other entity that operates the facility. (Note that this is not
referring to the Operator in Responsible Charge or ORC)
Name Meritech, Inc.
Mailing Address PO Box 27
City Reidsville
State / Zip Code NC
Telephone Number (336)342-4748
Fax Number (336)342-1522
4. Population served: 214
1 of 3 FomrA 4/05
NPDES APPLICATION FOR PERMIT RENEWAL - FORM A
For Publicly Owned Treatment Works (POTW) or other treatment systems treating
domestic wastes < 0.1 MGD with no pretreatment program.
9. Do you receive industrial waste?
I No ❑ Yes (if you have an approved pre-treatment program, must complete Form 2A)
4. Type of collection system
® Separate (sanitary sewer only) ❑ Combined (storm sewer and sanitary sewer)
4. Outfall Information:
Number of separate discharge points 2
Outfall Identification number(s) 001.002
Is the outfall equipped with a diffuser? ❑ Yes ® No
8. Name of receiving stream(s) (Provide a map showing the exact location of each outfall):
Deep River
8. Frequency of Discharge: ® Continuous ❑ Intermittent
If intermittent:
Days per week discharge occurs: Duration:
8. Describe the treatment system
List all installed components, including capacities, provide design removal for BOD, TSS, nitrogen and
phosphorus. If the space provided is not sufficient, attach the description of the treatment system in a
separate sheet of paper.
A Package Plant Consisting of one Manual Barscreen, One Aeration Basin with
Diffused Air from 2 Blowers, one Clarifier , V notch Weir for Manual Flow measurement,
one Chlorine Contact Chamber with Hypochlorite addition for disinvection
8. Flow Information:
Treatment Plant Design flow .01 MGD
Annual Average daily flow .002 MGD (for the previous 3 years)
Maximum daily flow .002 MGD (for the previous 3 years)
12. Is this facility located on Indian country?
❑ Yes ® No
2 of 3 Form -A 4/05
NPDES APPLICATION FOR PERMIT RENEWAL - FORM A
For Publicly Owned Treatment Works (POTW) or other treatment systems treating
domestic wastes < 0.1 MGD with no pretreatment program.
13. Effluent Data
Provide data for the parameters listed. Fecal Conform, Temperature and pH shall be grab samples, for all other
parameters 24-hour composite sampling shall be used. If more than one analysis is reported, report daily maximum
and monthly average. If only one analysis is reported, report as daily maximum.
Parameter
Daily
Maximum
Monthly
Average
Units of
Measurement
Biochemical Oxygen Demand (BOD5)
8.6
2.5
mg/1
Fecal Coliform
1
<1
ml
Total Suspended Solids
43
4.14
mg/1
Temperature (Summer)
28
15
C
Temperature (Winter)
pH
8.7
7.3
unit
13. List all permits, construction approvals and/or applications:
Type
Hazardous Waste (RCRA) NESHAPS (CAA)
UIC (SDWA) Ocean Dumping (MPRSA)
NPDES NC0000639 Dredge or fill (Section 404 or CWA)
PSD (CAA) Other
Non -attainment program (CAA)
Permit Number
15. APPLICANT CERTIFICATION
Type
Permit Number
I certify that I am fnmlliar with the information contained in the application and that to the
best of my knowledge and belief such information is true, complete, and accurate.
Deavk Lot; I
Printed name of Person Signing
Pre(CA evd-
Title
Signature of Applicant Date
North Carolina General Statute 143-215.6 (b)(2) states: Any person who knowingly makes any false statement
representation, or certification in any application, record, report, plan, or other document files or required to be
maintained under Article 21 or regulations of the Environmental Management Commission implementing that
Article, or who falsifies, tampers with, or knowly renders inaccurate any recording or monitoring device or method
required to be operated or maintained under Article 21 or regulations of the Environmental Management
Commission implementing that Article, shall be guilty of a misdemeanor punishable by a fine not to exceed
$25,000, or by imprisonment not to exceed six months, or by both. (18 U.S.C. Section 1001 provides a
punishment by a fine of not more than $25,000 or imprisonment not more than 5 years, or both, for a similar
offense.)
3of3 Form-A4'05
FACT SHEET FOR EXPEDITED RENEMAL
Permit Number
NC J 0°0 (n 1
Facility Name
V INAA
Reviewer
D (4-
�
Basin/Sub-basin
0 3 -- DUin/ (, ,�G
`
-
Receiving Stream
-of
Stream Classification in permit
Stream Classification in BIMS
7
Is the stream impaired (listed on 303(d))?
/.,10
Is stream monitoring required?
,\)�,
Does the permit need NH3 limit(s)?
0
the permit need TRC limit(s)?
YDoes
�� iii
Does the permit have toxicity testing?
\,
Are there special conditions?
y c->
Any obvious compliance concerns?
h,10
Existing Expiration Date
9 / 3 /b
New Expiration Date
c1/' O / /
Miscellaneous Comments:
If expedited, Is this a simper permit or a ore diffIcul ?one?