NC0003450_Permit Modification_19990927

NPDES DOCUHENT 5CANNINO COVER SHEET
NPDES Permit:
NC0003450
Wallace Plant WWTP
Document Type:
Permit Issuance
Wasteload Allocation
Authorization to Construct (AtC)
C"
Permit Modification ‘,
Complete File - Historical
Engineering Alternatives (EAA)
Correspondence
Owner Name Change
Instream Assessment (67b)
Speculative Limits
Environmental Assessment (EA)
Document Date:
September 27, 1999
This document is printed on reuse paper - ignore any
content on the reverse side

State of North Carolina
Department of Environment
and Natural Resources
Division of Water Quality
James B. Hunt, Jr., Governor
Bill Holman, Secretary
Kerr T. Stevens, Director
AT�
NCDENR
NORTH CAROLINA DEPARTMENT OF
ENVIRONMENT AND NATURAL RESOURCES
September 27, 1999
The Honorable Charles C. Farrior, Jr., Mayor
Town of Wallace
316 E. Murray Street
Wallace, North Carolina 28466
Subject: NPDES Permit Modification
Permit Numbe r NC0003450
Former Stevcoknit WWTP
Duplin County
Dear Mayor Farrior:
The Division issued NPDES permit number NC0003450 to Stevcoknit Fabrics Company on
September 30, 1996. The Division has reviewed your request for permit modification at the subject facility_
Specifically, you requested that the permit be transferred to the Town of Wallace as ownership of the
treatment facility has changed. In accordance with your permit modification request. the Division is
forwarding herewith a modification to the subject permit. This permit modification authorizes the Town of
Wallace to operate the former Stevcoknit Fabrics wastewater treatment facility at a flow rate of 4.42 MGD
with discharge to Little Rockfish Creek. Relocation of the outfall to the mainstem of Rockfish Creek must be
completed by July 31, 2001 as the permit will be renewed with the requirement to discharge at that location.
No extension will be granted beyond this date. Additionally, based on discussions between Division staff and
town personnel regarding devastation of the existing wastewater treatment facility from Hurricane Floyd, it
may not be in the Town's best interest to expend funds to repair that system. As such, the need for renewal of
NPDES permit number NC0020702 will be reviewed as more information regarding the current status of the
aforementioned facilities becomes available.
Enclosed please find the modified permit. This permit modification 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 December 6, 1983.
Please take notice that this permit is not transferable. Part II, E.4. addresses the requirements to be
followed in case of change in ownership or control of this discharge. This permit does not affect the legal
requirement to obtain other permits which may be required by the Division of Water Quality or permits
required by the Division of Land Resources. Coastal Area Management Act or any other Federal or Local
government permit that may be required.
1617 MAIL SERVICE CENTER, RALEIGH, NORTH CAROLINA 27699-1617 - TELEPHONE [phone]/FAX [phone]
AN EQUAL OPPORTUNITY AFFIRMATIVE ACTION EMPLOYER - 50% RECYCLED/ 10% POST -CONSUMER PAPER

If you have any questions concerning this permit, please contact Mr. Mark McIntire at telephone
number [phone], extension 553.
Sincerely
Original Signed By
David A. Goodrich
Kerr T. Stevens
Cc: NPDES Permit File
Wilmington Regional Office
Aquatic Toxicology Unit
Point Source Compliance/Enforcement Unit
EPA, Roosevelt Childress

Permit No. NC0003450
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,
Town of Wallace
is hereby authorized to discharge wastewater from a facility located at
Former Stevcoknit Fabrics Wastewater Treatment Plant
On NCSR 1939
Wallace
Duplin County
to receiving waters designated as Rockfish Creek 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, 1999.
This permit and authorization to discharge shall expire at midnight on July 31, 2001.
Signed this day September 27, 1999.
Original Signed By
David A. Goodrich
Kerr T. Stevens, Director
Division of Water Quality
By Authority of the Environmental Management Commission

4
Permit No. NC0003450
SUPPLEMENT TO PERMIT COVER SHEET
Town of Wallace
is hereby authorized to:
1. Operate an existing 4.42 MGD wastewater treatment system consisting of flow equalization.
dual aeration basins in parallel, two secondary clarifiers, disinfection via chlorination,
multimedia filters, filter backwash tank, effluent post aeration tank, aerated sludge digestion,
sludge thickening, and sludge drying beds located at the former Stevcoknit Wastewater
Treatment Plant on NCSR 1939 in Wallace. Duplin County; and
2. Discharge from said treatment works at the location specified on the attached map into Little
Rockfish Creek a class C swamp water in the Cape Fear River Basin.

County
Mental Health Ctr
-� Ali I
II
ACem n u •
l
rpal
uil. ng
Hend erson^
Field
Armory* .
Poston Ch
BM`"•17.4
Latitude:
Longitude:
Ouad #:
Stream Class:
Receiving Stream:
Permitted Flow:
SCALE 1:24000
34°43'52"
77'58'56"
I27NW
CSw
Rockfish Creek
4.42 MGD
,Sub -Basin:
03-06-22
Riverbark •
Town of Wallace
NC0003450
Stevcolmit Wastewater Treatment Plant

A (1). EFFLUENT LIMITATIONS AND MONITORING REQUIREMENTS - FINAL
Permit No. NC0003450
During the period beginning on the effective date of the permit and lasting until expiration, the Permittee is authorized to discharge from outfall(s) serial number 001-
Wastewater Treatment Plant Effluent. Such discharges shall be limited and monitored by the Permittee as specified below:
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Flow (MGD)
4.42
Continuous
Recording
I or E
BOD. 5-Day. 20°C (April 1 - October 31)2
5.0 mg/L
7.5 mg/L
Daily
Composite
I, E
BOD, 5-Day, 20°C (November 1 - March 31)2
10.0 mg/L
15.0 mg/L
Daily
Composite
I, E
Suspended Residue'
30.0 mg/L
45.0 mg/L
Daily
Composite
I, E
_Total
NH3 as N (April 1 - October 31)
1.0 mg/L
Daily
Composite
E
NH3 as N (November 1 - March 31)
2.0 mg/L
Daily
Composite
E
Dissolved Oxygen'
Daily
Grab
E, U, D
Fecal Coliform (geometric mean)
200/100 ml
400/100 ml
Daily
Grab
E, U. D
Total Residual Chlorine
27 pg/L
Daily
Grab
E
Temperature
Daily
Grab
E, U. D
Conductivity
Daily
Grab
E, U, D
Total Phosphorus
Monthly
Composite
E
Total Nitrogen (NO2+NO3+TKN)
Monthly
Composite
E
pH4
Daily
Grab
E
Chronic Toxicity'
Quarterly
Composite
E
NOTES:
Sample Locations: I — Influent. E — Effluent, U — (1) upstream at USGS gage on Little Rockfish Creek, (2) Rockfish Creek upstream of the confluence with Little Rockfish Creek.
D - Downstream (1) at the mouth of Little Rockfish Creek. (2) Rockfish Creek at the 1-40 Bridge. Upstream and downstream samples shall be grab samples collected 3/Week
during the months of June. July, August. and September and Weekly during the remainder of the year.
2 The monthly average effluent BOD5 and total suspended residue concentrations shall not exceed 15% of their respective influent values (85% removal).
3 The daily average effluent dissolved oxygen concentration shall at no time be less than 6.0 mg/L.
4 The pH shall not be less than 6.0 standard units or greater than 9.0 standard units.
5 Chronic Toxicity (Ceriodaphnia) Pass/Fail @ 90%: January. April. July. October; See condition A(2) of this permit.
THERE SHALL BE NO DISCHARGE OF FLOATING SOLIDS OR VISIBLE FOAM IN OTHER THAN TRACE AMOUNTS.

Permit No. NC0003450
SUPPLEMENT TO EFFLUENT LIMITATIONS
AND MONITORING REQUIREMENTS
SPECIAL CONDITIONS
A (2). CHRONIC TOXICITY PERMIT LIMIT (QUARTERLY) — 4.42 MGD
The effluent discharge shall at no time exhibit observable inhibition of reproduction or significant mortality to
Ceriodaphnia dubia at an effluent concentration of 90%.
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 I1 Chronic Whole Effluent Toxicity Test Procedure" (Revised -February 1998) or subsequent versions.
All toxicity testing results required as part of this permit condition will be entered on the Effluent Discharge
Monitoring Form (MR-1) for the months in which tests were performed, using the parameter code TGP3B for
the pass/fail results and THP3B for the Chronic Value. Additionally, DWQ Form AT-3 (original) is to be sent
to the following address:
Attention: Environmental Sciences Branch
North Carolina Division of
Water Quality
1621 Mail Service Center
Raleigh, North Carolina 27699-1621
Completed Aquatic Toxicity Test Forms shall be filed with the Environmental Sciences Branch no later than 30
days after the end of the reporting period for which the report is made.
Test data shall be complete, accurate, include all supporting chemical/physical measurements and all
concentration/response data, and be certified by laboratory supervisor and ORC or approved designate
signature. Total residual chlorine of the effluent toxicity sample must be measured and reported if chlorine is
employed for disinfection of the waste stream.
Should there be no discharge of flow from the facility during a month in which toxicity monitoring is required,
the permittee will complete the information located at the top of the aquatic toxicity (AT) test form indicating
the facility name, permit number, pipe number, county, and the month/year of the report with the notation of
"No Flow" in the comment area of the form. The report shall be submitted to the Environmental Sciences
Branch at the address cited above.

Permit No. NC0003450
SUPPLEMENT TO EFFLUENT LIMITATIONS
AND MONITORING REQUIREMENTS
SPECIAL CONDITIONS
(continued)
Should the permittee fail to monitor during a month in which toxicity monitoring is required. monitoring will
be required during the following month.
Should any test data from this monitoring requirement or tests performed by the North Carolina Division of
Water Quality indicate potential impacts to the receiving stream, this permit may be re -opened and modified to
include alternate monitoring requirements or limits.
NOTE: Failure to achieve test conditions as specified in the cited document, such as minimum control
organism survival, minimum control organism reproduction, and appropriate environmental controls, shall
constitute an invalid test and will require immediate follow-up testing to be completed no later than the last day
of the month following the month of the initial monitoring.

FACT SHEET ADDENDUM
NPDES No. NC0003450
SEPTEMBER 27, 1999
The purpose of this addendum is to provide additional information regarding the major permit
modification to the former Stevcoknit Fabrics WWTP permit under NPDES permit number
NC0003450.
Stevcoknit Fabrics Company formerly operated a textile facility (including its own wastewater
treatment plant) in the Town of Wallace. The textile plant discharge under NPDES permit number
NC0003450. The plant recently closed down and was given to the Town. In early 1998, the Town
contracted the Wooten Company to conduct an engineering evaluation of the treatment system to
determine its actual treatment capacity. The Town is actively trying to recruit an industry to take
over the former Stevcoknit facility so as to stimulate the local economy. Additionally, the Town
would like to maintain the wastewater treatment plant so that it can have additional capacity for any
other users wishing to connect.
A condition of the draft permit was that the outfall from this facility be relocated to the mainstem of
Rockfish Creek prior to discharge_ Hurricane Floyd inundated Wallace's existing facility, making it
unusable. As a result, the final NPDES permit for the former Stevcoknit facility will allow the town
to discharge to Little Rockfish Creek for 21 months (when the permit expires). Upon renewal in
2001, the permit will reflect a discharge to Rockfish Creek. This is, more or less, a compliance
schedule allowing the Town to secure funding and complete construction of the outfall relocation to
Rockfish Creek.
Fact Sheet Addendum — NC0003450
McIntire

AFFIDAVIT OF PUBLICATION
NORTH CAROLINA.
Wake County. ) Ss.
PUBLIC NOTICE
STATE OF NORTH CAROLINA
ENVIRONMENTAL MANAGEMENT
COMMISSION
POST OFFICE BOX 29535
RALEIGH, NORTH CAROLINA 27626-0535
NOTIFICATION OF INTENT TO ISSUE A STATE NPDES
PERMIT
On the basis of thorough staff review and application of Article 21
of Chapter 143, General Statutes of North Carolina, Public Law
92-500 and other lawful standards and regulations, the North
Carolina Environmental Management Commission proposes to
issue a permit to discharge to the persons listed below effective
9/27/99 and subject to special conditions.
Persons wishing 10 comment upon later or object to the proposed
determinations are invited to submit same in writing to the above
address no later than 9/27/99. All comments received prior to that
date will be considered In the formulation of final determinations
regarding the proposed permit. A public meeting may be held
where the Director of the Division of Environmental Manage-
ment finds a significant degree of public interest in a proposed
Permit. -__ _ _ __
A copy of the draft permit is available by writing or calling the
Division of Environmental Management, P.O. Box 29535, Ra-
leigh, North Carolina 27626-0535, [phone].
The application and other information may be Inspected at these
locations during normal office hours. Copies of the information
on file are available upon request and payment of the costs of
reproduction. All such comments or requests regarding a pro-
posed Permit should make reference to the NPDES permit
number listed below.
Date: 8y11/99
/s/ David A. Goodrich for
A. Preston Howard, Jr., P.E. Director
Division of Environmental Management
Public notice of intent to Issue a State NPDES permit to the
following:
1. NPDES No. NC0003450. The Town of Wallace, 316 East Murray
Street, Wallace, NC 29466 has applied fora permit modification
for the former Stevcoknit.Fabrics facility in Wallace. The Town
will now own and operate the wastewater treatment facility at
the former fabrics plant. The facility is permitted todischarge up
to 4.42 MGD of treated domestic and industrial wastewater from
a single outfall into Rockfish Creek, a Class C-Swamp stream in
the Cape Fear River Basin which has a 7g10 flow of 16.0 cfs.
Discharge through from This facility is not authorized until the
outfall has been relocated to Rockfish Creek. BOD and ammonia
are water quality limited. For some parameters, the available
load capacity of the immediate receiving water will be con-
sumed. This may affect future water quality based effluent
limitations for additional dischargers within this portion of the
watershed.
N&0: August 16, 1999
Before the undersigned, a Notary Public of said
County and State, duly commissioned and authorized to
administer oaths, affirmations, etc., personally appeared
Patricia L. Robinson who, being duly sworn or affirmed,
according to law, doth depose and say that she is Billing
Manager -Legal Advertising of THE NEWS AND
OBSERVER PUBLISHING COMPANY a corporation
organized and doing business under the Laws of the State of
North Carolina, and publishing a newspaper known as THE
NEWS AND OBSERVER, in the City of Raleigh, County and
State aforesaid, 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 of the requirements and qualifications of Section
1-597 of the General Statutes of North Carolina and was a
qualified newspaper within the meaning of Section 1-597 of
the General Statutes of North Carolina, and that as such she
makes this affidavit; that she is familiar with the books, files
and business of said corporation and by reference to the files
of said publication the attached advertisement for NC
DIVISION OF W was inserted in the aforesaid newspaper on
dates as follows: 08/16/99
Account Number: 73350831
The above is correctly copied from the books and files of the aforesaid Corporation and publication.
Billing Manager -Legal Advertising
Sworn or affirmed to, and subscribed before me, this
17 day of AUGUST , 1999 AD
In Testimony Whereof, I have hereunto set my hand
and affixed my official seal, the day and year aforesaid.
e/h/n,
Notary Public
My commission expires 2nd day of July 2000.

MEMORANDUM
To:
From:
NCDENR/DIVISION OF WATER QUALITY
Water Quality Section/NPDES Unit
April 8, 1999
t—
Rick Sl—cer.
WiRO — Water Quality Supervisor
Mark McIntire
NPDES Unit
RECEIVED
ED
APR 12 1999
BY:
JUL 2 ? 1,„
DENR - WATER QUALITY
POINT SOURCE BRANCH
Subject: Town of Wallace/Stevcoknit Fabrics Permit Modification
NC0003450 - Duplin County
Attached with this memorandum is a draft NPDES permit for the following facility:
iU
NPDES Permit #
Facility Name
County
NPDES Contact
NC0003450
Town of Wallace -
Stevcoknit facility
Duplin
Mark TVlclntire
Please have your appropriate staff member review the draft permit and forward any comments to
me.
Thanks for you assistance.
cc: Mark McIntire — Permit File
Or?
K/)
CO.-er
7(27/97

DENR/DWQ
FACT SHEET FOR NPDES PERMIT DEVELOPMENT
NPDES No. NC0003450
Facility InformatioA
Applicant/Facility Name:
Town of Wallace - Stevcoknit Wastewater Treatment Plant
Applicant Address:
316 East Murray Street, Wallace, NC 28466
,Facility Address:: `'`: •
NCSR 1939, Wallace, NC
:Permitted Flow
4.42 MGD
;Type' of Waste: ., .
100% domestic
Faciiity/Permit Status:
Modification / Name Change
'County:
Duplin
Miscellaneous
(Receiving'Streami,
Rockfish Creek
F•Regiona►i Office: •
Wilmington
,Stream Classification: :
C-Swamp
`'USGS Topo Quad:.
127NW
303(d) Listed?:
NO
:"Permit Writer:
Mark McIntire
'Subbasin:
03-06-22
:Date:'
April 8, 1999
..:Drainage Area (mi2):.
161.6
Summer 7Q14; (cfs) ,
4.2
Winter 7Q 10 (cis):
16
-Average Flow (cis):
226
IWC (%) - 4.42 MG -
62%
Primary SIC Code: f
4952
SUMMARY
Stevcoknit Fabrics Company formerly operated a textile facility (including its own wastewater
treatment plant) in the Town of Wallace. The textile plant discharge under NPDES permit number
NC0003450. The plant recently closed down and was given to the Town. In early 1998, the Town
contracted the Wooten Company to conduct an engineering evaluation of the treatment system to
determine its actual treatment capacity. The Town is actively trying to recruit an industry to take
over the former Stevcoknit facility so as to stimulate the local economy. Additionally. the Town
would like to maintain the wastewater treatment plant so that it can have additional capacity for any
other users wishing to connect.
Although the Stevcoknit permit had a flow limit of 5.0 MGD, the engineering evaluation determined
that the plant was actual able to treat only 4.42 MGD due to the size of the secondary clarifiers. It is
the Town's intent to modify the equalization basin, making it an aerobic reactor capable of treating
anywhere from 0.25 to 0.9 MGD of domestic wastewater diverted from the Town's existing
treatment system. In the event that domestic wastewater is diverted to this facility, influent screening
and grit removal will need to be provided.
A condition of this permit modification is that the outfall from this facility be relocated to the
mainstem of Rockfish Creek.
TOXICITY TESTING:
Quarterly Chronic Toxicity Testing @ 62%
COMPLIANCE SUMMARY:
This facility has no compliance history as it has not treated the Town's domestic wastewater.
Penman Heights Fact Sheet
NPDES Renewal
Page t

INSTREAM MONITORING:
Upstream and downstream monitoring will be conducted for dissolved oxygen, fecal coliform,
conductivity and temperature. Monitoring locations are the same as those in the Stevcoknit permit.
PROPOSED CHANGES:
• Name Change: The name listed on the permit has been changed to the Town of Wallace.
• Effluent Limitations: The effluent limitations for BOD; and NH;-N have been modified to reflect
the current permitting strategy for facilities discharging in the Cape Fear River Basin.
• Toxicity Testing: The toxicity testing requirement has been modified to reflect the new IWC of
the discharge at the proposed relocated outfall. The IWC at this location is 62%.
• TRC: A total residual chlorine limitation has been installed in accordance with the mass balance
calculation and the 1714/L standard.
PROPOSED SCHEDULE FOR PERMIT ISSUANCE:
Draft Permit to Public Notice: April 21, 1999
Permit Scheduled to issue: June 7, 1999
STATE CONTACT:
If you have any questions on any of the above information or on the attached permit, please contact
Mark McIntire at [phone] ext. 553.
NPDES UNIT COMMENT:
NAME: DATE:
REGIONAL OFFICE COMMENT: [) U - GL-E L t j A
NAME: t-1,
y DATE: l C( C
Penman Heights Fact Sheet
NPDES Renewal
Page 2

The November 3, 1998
Wooten Mr. David A. Goodrich _-
Company Supervisor, NPDES Unit >A 6'f ` ,tv
s� Water Quality Unit < t
yi
P. O. Box 29535 Cu U>ye -44 N' „.t,
Engineering Raleigh, North Carolina 27626-0535 'K J 4,P/
Planning Re: NPDES Application
6,,, 0- it
Former Stevcoknit Fabrics Plant/Town of Wallace Plant
Architecture TWC #2798
120 N. Boylan Avenue
Raleigh, NC
27603
919-828-0531
Fax: [phone]
Since 1936
✓2.
i
Dear Mr. Goodrich:
Your letter of October 23, 1998 was received on October 28, 1998 and listed seven (7)
unnumbered comments and concerns. Responses to the comments and concerns
follow, with the number of each response corresponding to the order in which the
comment/question appeared in your letter.
1. The proposed rating on the plant of 4.42 MGD is based on limiting the overflow rate
on the two existing clarifiers to 500 gal/day/sq. ft.. Well operated treatment plants,/
receiving mostly domestic wastewater can meet effluent limits like those expected for
Wallace at this overflow rate without equalization. The two existing aeration basins
would have a hydraulic retention time of 20 hours at 4.42 MGD and 480
horsepower of mechanical aeration. This HRT and aeration capacity would be
adequate to treat wastewater considerably stronger than typical domestic wastewater
at maximum month average flows of 4.42 MGD without consideration of the
equalization basin. Actually, the plan calls for converting the equalization basin to an
aerobic reactor to be used at plant loading and flows in the 0.25 - 0.9 MGD range.
Clarifier capacity would still limit overall plant capacity. Since return activated
sludge can and will be added to what is now called an equalization basin, there is no
reason not to count it as biological reactor volume since it will function as a
bioreactor.
The need for screening and grit removal facilities has been recognized. Screening
facilities are recommended if part of the flow from the existing town outfall is
diverted into the equalization basin (after modifications). If as little as 0.25 MGD is
diverted, it would likely be diverted using a side channel weir which would cause
grit to flow by the diversion and not into this plant. Aerated grit removal facility
costs for a larger scale diversion are already shown in the report (see itemized cost
projection on the bottom of page 12).
V3. These are pressure filters with influent pumps having a capacity of 1,800 gpm each.
It is doubtful that effluent filtration would be needed when the plant is only partially
loaded. Intermittent operation at 1,800 gal/min. may not improve effluent water
quality and would significantly increase operational cost. It would be reasonable to
allow operational flexibility - at least until the plant flow reaches an average 1,800
gal/min. (2.6 mgd). Note that this is an existing and not a new facility.
/4. Piping modifications required to use the existing equalization basin as the aerobic
reactor could leave the existing configuration intact so that if there is a failure of the
converted equalization basin, either of the existing aeration basins could be placed in

Mr. David A. Goodrich
page 2
November 3,1998
service along with its associated clarifier. This provides the equivalent of a triple
train and exceeds the dual train requirement in our opinion. It is noted that if the only
source of wastewater to the facility is from the Town of Wallace interceptor, the
diversion of influent flow could simply be stopped.
5. The reason for the policy is understood; however, this is an existing permitted
facility which would require substantial modification to chlorinate following
filtration. An additional consideration is that the pressure filters may require at least a
preliminary chlorine dose in order to eliminate organic growth in the filter media.
When the plant is only partially loaded, very low solids are expected from the
secondary clarifier so the problem should be minimized.
6. Page 8 of the report suggests that no attempt be made to operate the plant at flows
less than 0.25 MGD. This would be the minimum amount which would be diverted
from the Town plant (0.25 MGD might also be the maximum diverted from the town
plant). 1.5 MGD is the maximum which could be treated in the converted
equalization basin. When flow exceeds 1.5 MGD, it will be necessary to place one
of the existing aeration basins in service. The report never states that as much as 1.5
MGD of flow will be necessary to put the plant back in service, and, as noted earlier
and in the report, definitively states that the plant can be operated with as little as
0.250 MGD of flow.
7 . It is not proposed to remove the tertiary filtration facilities. If the filters are needed to
meet effluent requirements, they would be placed in service.
It is trusted that this information satisfactorily addresses all your questions and
concerns. You should expect to receive a final permit application from the Town in the
near future.
Sincerely,
THE WOO C MPANY
Ford Chambhss
cc: Town of Wallace

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State of North Carolina
Department of Environment
and Natural Resources
Division of Water Quality
James B. Hunt, Jr., Governor
Wayne McDevitt, Secretary
A. Preston Howard, Jr., P.E., Director
October 23, 1998
Mr. Everette L. Chambliss, Jr.. P.E.
The Wooten Company
120 North Boylan Avenue
Raleigh, North Carolina 27603
4/'CO003 Ll 5d
AVIA
NCDENR
Subject: Comments re: Draft NPDFS Application
Former Stevcoknit Fabrics Plant
Duplin County
Dear Mr. Chambliss:
This letter is in response to your draft NPDES permit application submitted for the former
Stevcoknit Fabrics Plant in Wallace. We appreciate the opportunity to review the City's plans for
the former Stevcoknit plant while those plans are still in draft form.
The submitted engineering evaluation of the aforementioned facility provided excellent detail
and background. A thorough staff review has raised the following questions and/or concerns:
• It is not common engineering practice to include equalization volume as biological
reactor volume. The purpose of equalization is one of hydraulic control, not biological
treatment. If the equalization volume is not included in the calculation of biological
reactor volume, the actual treatment plant capacity is approximately 3.7 MGD.
• The Division would require installation of fine screening and grit removal should the
existing facilities be used for municipal wastewater treatment. This cost should be
factored into the cost of possible operational contingencies contained in the report.
• There is currently a bypass line around the tertiary filters. Bypasses around major
treatment units are illegal and should be removed prior to any future operation.
• The plan for operating the facility in an underloaded mode does not provide dual train
treatment as required by North Carolina Administrative Code. Please explain how the
plant would be operated in times of maintenance and/or equipment failure.
• As illustrated in the engineering evaluation, it appears that tertiary filtration occurs
downstream of disinfection. Current DWQ policy dictates that, wherever feasible,
tertiary filtration be installed upstream of chlorine disinfection.
P.O. Box 29535, Raleigh, North Carolina 27626-0535 Telephone [phone] FAX [phone]
An Equal Opportunity Affirmative Action Employer 50% recycled / 10% post -consumer paper

1
• The report indicates that diversion of as much as 1.5 MGD of wastewater from the
Town's collection system may be necessary to put the former Stevcoknit facility back into
service. It is unclear where the 1.5 MGD might come from as the Town is currently
permitted for only 1.0 MGD. Furthermore, the Town used public monies through the
Construction Grants and Loans (CG&L) program for its existing facility. It is
recommended that any planned diversions be discussed with CGd2L.
• Is should be demonstrated that a low weir overflow rate for the clarifiers eliminates the
need for tertiary filtration.
I would like to compliment you on your attention to operation under low flow scenarios.
This is an important aspect of treatment plant performance and is all too often overlooked. Thank
you again for giving us an opportunity to review this proposal in draft form. If you have any
questions, comments or concerns regarding this response, feel free to contact Mark McIntire at
[phone], extension 553.
Sincerely,
David A. Goodrich
9"64‘it
Supervisor, NPDES Unit
Water Quality Section
cc: Central Files
NPDES Unit Files (w/attachments)
Wilmington Regional Office — Water Quality
Bobby Blowe, Construction Grants and Loans Section

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Wooten
Company
ems. Mr. David Goodrich,
North Carolina Division of Water Quality
Engineering P. O. Box 29535
Raleigh, North Carolina 27626-0535
Planning
Architecture Re: Wastewater Treatment Study & NPDES Permit Modification Request
Wallace, North Carolina
TWC #2798
Dear Mr. Goodrich:
Enclosed please find a draft application for an NPDES Permit Modification for the
former Stevcoknit Fabrics Plant (NPDES Permit Number NC0003450). Also
enclosed is an engineering study which we believe addresses the issues that your
office raised at our meeting on July 14, 1998. The permit application is on Standard
120 N. Boylan Avenue Form A rather than Form C since a municipality will take over the operation.
Raleigh, NC
27603 Please review the enclosed material and then give me a call. The situation is unusual
enough that I thought it best to make this informal preliminary submittal. We can
then make any changes to the application form you feel necessary, and make a
formal application, with filling fee, etc., once we are sure that we have given you
all the information you will need to process the application.
919-828-0531
Fax: [phone] Sincerely,
THE WOOTE COMPANY
ex
Since 1936
August 24, 1998
Ford Chambliss
FC:fc
Enclosure

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NORTH CAROLINA DEPT. OF NATURAL & ECOMIMIC RESOURCES
ENVIRONMENTAL MANAGEMENT COMMISSION
NATIONAL POLLUTANT DISCHARGE ELIMINATION SYSTEM
APPLICATION FOR PERMIT TO DISCHARGE WASTEWATER
• STANDARD FORM A — MUNICIPAL
FOR AGENCY USE
7,..:
SECTION I. APPLICANT AND FACILITY DESCRIPTION
Unless otherwise specified on this form all Items are to be completed. If an Item Is not applicable indicate 'NA.'
ADDITIONAL INSTRUCTIONS FOR SELECTED ITEMS APPEAR IN SEPARATE INSTRUCTION BOOKLET AS INDICATED. REFER TO
BOOKLET BEFORE FILLING OUT THESE ITEMS.
1. Legal Name of Applicant
(see Instructions)
2. Mailing Address of Applicant
(see instructions)
Number & Street
City
State
Zip Code
3. Applicant's Authorized Agent
(see Instructions)
Name and Title
Number & Street
City
State
Zip Code
Telephone
4. Previous Application
If a previous appllcatlon for a per-
mit under the National Pollutant
Discharge Elimination System has
been made, give the date of
appllcatlon.
let
;103*
10ata
Ole
1030
>oal
.1031
=104
Please Print or Type
City of Wallace
316 E. Murray Street
Wallace
NC
28466
Charles C. Farrior, Jr.
Mayor
316 E. Murray Street
Wallace
NC
28466
[phone]
Area Number
Code
YR MO DAY
1 certify that I am familiar with the information contained In this application and that to the best of my knowledge and belief such Information
Is true, complete, and accurate.
Charles C. Farrior, Jr.
Printed Name of Person Signing
Signature of Applicant or Authorized Agent
1024
1021
Mayor
Title
YR MO DAY
Date Application Signed
•
lort_^ Carolina General Statute 143-215.6 (b) (2) provides that: Any person who knowingly Makes
my false statement representation, or certification in any application, record, report, plan,
Ir other document files or required to be maintained under Article 21 or regulations of the
:rvironmental Management Commission imolerenting that Article, or who falsifies, tampers with,
)r kmawly renders inaccurate any recording or monitoring device or method required to be
)perated 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
510,000, or by imprisonment not to exceed six months, or by both. (18 U.S.C. Section 1001 provide
punishment by a fine of not more than S10,000 or imprisonment not more than 5 years, or both,
for a similar offense.)

S. Facility (see instructions)
Give the name. ownership. and physi-
cal location of the plant or other
operating facility where discharge(s)
presently occur(s) or will occur.
Name
Ownership (Public. Private or
Both Public and Private).
('IleLk biock if a Federal facility
and give GSA Inventory Control
Number
Location:
Number & Street
City
County
State
6. Discharge to Another Municipal
Facility (see Instructions)
a. Indicate If part of your discharge
is Into a municipal waste trans-
port system under another re-
sponsible organization. If yes.
complete the rest of this Item
and continue with Item 7. If no,
,go directly to Item 7.
b. Responsible Organization
Receiving Discharge
Name
Number & Street
City
State
Zip Code
c. Facility Which Receives Olscharge
Give the name of the facility
(waste treatment plant) which re-
ceives and Is ultimately respon-
sible for treatment of the discharge
from your facility.
d. Average Daily Flow to Facility
(mgd) Give your average daily
flow Into the receiving facility.
7. Facility Discharges, Number and
Discharge Volume (see instructions)
Specify the number of discharges
described In this application and the
volume of water discharged or lost
to each of the categories below.
Estimate average volume per day in
million gallons per day. Do not in-
clude Intermittent or noncontinuous
overflows. bypasses or seasonal dis-
charges from lagoons, holding
ponds. etc.
100D
1011e
10lt1
10Se
10S
lOSS
NSA..
10i11
-10ib
10So
1044
10So-
10Sf
1011;.
10(1t
I FOR AGENCY USE
r
City of Wallace
® PUB ❑ PRV ❑ BPP
❑ FED
N/A
615 Wilmington Road
Wallace
Duplin
NC
❑ Yes gj No
r
mgd
I-2

To: Surface Water
Surface Impoundment with
no Effluent
Underground Percolation
Well (Injection)
Other
Total Item 7
1f 'other' Is specified. describe
If any of the) discharges from this
facility are Intermittent, such as from
overflow or bypass points, or are
seasonal or periodic from lagoons,
holding ponds, etc., complete Item 8.
S. Intermittent Discharges
a. Facility Dypass points
Indicate the number of bypass
points fcr the facility that are
discharge polnts.(seo Instructions)
b. Facility Overflow Points
Indicate the number of overflow
points to a surface water for the
facility (see Instructions).
c. Seasonal or Periodic Discharge
Points Indicate the number of
points where seasonal discharges
occur from holding ponds,
lagoons, etc.
9. Collection System Type
Indicate the type and length (In
miles) of the collection system used
by this facility. (see Instructions)
Separate Storm
Separate Sanitary
Combined Sanitary and Storm
Both Separate Sanitary and
Combined Sewer Systems
Both Separate Storm and
Combined Sewer Systems
Length
10. Municipalities or Areas Served
(see instructions)
Total Population Served
107a1
10761
10791
107d1
107a1
107f1
107q1
Number of Total Volume Discharged,
Discharge Points Million Gallons Per Day
N/A
107a2 4.42
107b2 N/A
107c2 N/A
10742 N/A
'107a2 N/A
10if2 4.42
FOR AGENCY USE
100a None
t0$b None
10110.. None
109a
1020
110a
110a
110a
110a
110a
I I SST
® SAN
❑ CSS
❑ BSC
❑ SSC
_miles
Actual Population
Name Served
Town of Wallace
1100
110b
1100
110b
1100
110c
1-3

11. Average Daily Industrial Flow
Total estimated average daily waste
flow from all Industrial sources.
Initial 0 MGD
projected mgd
r 7maximum 4.42
Note: All major Industries (as defined In Section IV)
discharging to the municipal system must be
listed In Section IV.
FOR AGENCYUSE
12. Permits, Licenses and Applications
List all existing, pending or denied permits, licenses and applications related to discharges from this facility.(see instructions)
2.
3.
Issuing Agency
For
Agency Use
Type of Permit
or License
ID Number
Date
Filed
Y R/MO/DA
Date
Issued
Y R/MO/DA
Date
Denied
Y F !MO/DA
Expiration
Date
Y R/MO/DA
(a):
(b)
.: {cl
:;: (a).
(e} .:::.::::;•
(f)
(g) -
(h)_
•
13. Maps and Drawings
Attach all required maps and drawings to the back of thls application. (see Instructions)
14. Additional Information
114
Item
Number
Information
N/A
1-4

STANDARD FORM A —MUNICIPAL
FOR AGENCY USE
SECTION II. BASIC DISCHARGE DESCRIPTION
Complete this section for each present or proposed discharge indicated In Section 1, Items 7 and 8. that Is to surface waters. This includes
discharges to other municipal sewerage systems In which the waste water does not go through a treatment works prior to being discharged to
surface waters. Discharges to wells must be described where there are also discharges to surface waters from this facility. Separate
descriptions of each discharge ars required even If several discharges originate In the same facility. Ail values for ars existing discharge should
be representative of the twelve previous months of operation. If this Is a proposed discharge. values should reflect bast engineering estimates.
ADDITIONAL INSTRUCTIONS FOR SELECTED ITEMS APPEAR IN SEPARATE INSTRUCTION BOOKLET AS INDICATED. REFER TO
BOOKLET BEFORE FILLING OUT THESE ITEMS.
1. Discharge Serial No. and Name
a. Discharge Serial No.
(see Instructions)
b. Discharge Name
Give name of discharge. If any •
(see instructions)
c. Previous Discharge Serial No
If a previous NPDES permit
application was made for this dis-
charge (Item 4. Section 1) provide
previous discharge serial number.
2. Discharge Operating Dates
a. Discharge to Begin Date
If the discharge has never
occurred but Is planned for some
future date, give the date the
discharge will begin.
b. Discharge to End Date 1f the dis-
charge Is scheduled to be discon-
tinued within the next 5 years.
give the date (within best estimate)
the discharge will end. Give rea-
son for discontinuing this discharge
in Item 17.
S. Discharge Location Name the
political boundaries within which
the point of discharge Is located:
State
County
(If applicable) City or Town
4. Discharge Point Description
(sae Instructions)
Discharge Is Into (check one)
Stream (Includes ditches. arroyos,
and other watercourses)
Estuary
Lake
Ocean
Well (Injection)
Other
If 'other' Is checked, specify type
S. Discharge Point — Lat/Long.
State the precise location of the
point of discharge to the nearest
second. (see Instructions)
Latitude .
Longltude
l01a
M0/b
tat
2020
t0tb.
M03a
2030
:ii3o
200
•,.
::seal
001
WWTP Discharge
002
55 01
YR MO
N/A
YR MO
NC
Duplin
Town of Wallace
eg STR
❑ EST
❑ LKE
❑ OCE
❑ WEL
❑ OTH
Mar
O03f
Agency Use
.34 DEG. 43 MIN. 50 SEC
77 DEG. 59 MIN. 00 SEC
* Old discharge point on
Little Rockfish Creek.
Discharge is expected to
be moved to Rockfish,Creek
Lat.34° - 43' - 00"
Long. 77° - 58' - 45"
This section contains 8 pages.

16,
6. Discharge Receiving Water Name
Name the waterway at the point of
dlscharge.(see Instructions)
If the discharge Is through an out -
(all that extends beyond the shoreline
or is below the mean low water line,
complete Item 7.
7. Offshore Discharge
a. Discharge Distance from Shore
b. Discharge Depth Below Water
Surface
IOSA
t00b
207s
207b
DISCHARGE SERIAL NUMBER
001
FOR AGENCY USE
i
Little Rockfish Creek, expected to move to
Rockfish Creek
For Agency Use
I
Minor 1
Suns
1111
N/A
N/A
feet
feet
If discharge is from a bypass or an overflow point or is a seasonal discharge from a lagoon. holding pond. etc., complete Items 8. 9 or 10.
as applicable, sand continuo with item 11.
s. Bypass Discharge (see instructions) N/A
a. Bypass Occurrence
Check when bypass occurs
Wet weather
Dry weather
b. Bypass Frequency Give the
actual or approximate number
of bypass incidents per year.
Wet Weather
Dry weather
c. Bypass Duration Give the
average bypass duration in hours.
Wet weather
Dry weather
d. Bypass Volume Give the
average volume per bypass Incident.
In thousand gallons.
Wet weather
Dry weather
e. Bypass Reasons Give reasons
why bypass occurs.
Proceed to Item 11.
9. Overflow Discharge (see instructions)
a. Overflow Occurrence Check
when overflow occurs.
Wet weather
Dry weather
b. Overflow Frequency Give the
actual or approximate incidents
per year.
Wet weather
20Sa1
twat
20Sb1
202bt
200
*0141
20S42
201•
20fa1
201142
t01ib 1
❑ Yes 0 No
❑ Yes ❑ No
times per year
times per year
hours
h.3u rs
thousand gallons per incident
thousand gallons per incident
N/A
❑ Yes ❑ No
❑ Yes ❑ No
times per year
Dry weather
200b2
times per year
11-2

DIE -CHARGE SERIAL NUMBER
FOR AGENCY USE
c. Overflow Duration Give the
average overflow duration In
hours.
Wet weather
Dry weather
d. Overflow•Voluma Give the
average volume per overflow
incident In thousand gallons.
Wet weather
Dry weather
Proceed to Item 11
10. SeasonaVPeriodlc Discharges
Seasonal,/Periodic Discharge
Frequency if dlscharge Is Inter-
mittent from a holding pond.
lagoon. etc., give the actual or
approximate number of times
this discharge occurs per year.
b. Seasonal/Periodic Discharge
Volume Give the average
volume per discharge occurrence
In thousand gallons.
c. Seasonal/Periodic Discharge
Duration Give the average dura-
tion of each discharge occurrence
In days.
d. Seasonal/Periodic Discharge
Occurrence —Months Check the
months during the year when
the discharge normally occurs.
11. Discharge Treatment
a. Discharge Treatment Description
Describe waste abatement prac-
tices used on this discharge with
a brief narrative. (See instruc-
tions)
hours
H 3u rs
N/A
thousand gallons per Incident
thousand gallons per Incident
times per year
days
thousand gallons per discharge occurrence
❑JAN ❑FEB ❑MAR
❑APR CI MAY 0JUN
DJUL 0 AUG ❑SEP
❑ OCT 0 NOV ❑ DEC
Treatment starts with equilization and aeration basins
followed by clarifiers. Chlorination is provided before
water is filtered, aerated and released. Sludge is
treated by aerobic digestors, sludge gravity thickeners and
sludge, drying beds.
11-3

b. Discharge Treatment Codes
Using the codes listed In Table I
of the Instruction Booklet.
describe the waste abatement
processes applied to this dis-
charge in the order In which
they os.cur. if possible.
Separate all codes with commas
except where slashes are used
to designate parallel operations.
If this discharge Is from a municipal waste
treatment plant (not an overflow or
bypass). complete items 12 and 13
12. Plant Design and Operation Manuals
Check which of the following are
currently assailable
a. Engineering Design Report
b. Operation and Maintenance
Manual
13. Plant Design Data (see instructions)
a. Plant Design Flow ( mgd:)
b. Plant Design BOO Removal (%)
c. Plant Design N Removal (%)
d. Plant Design P Removal (%)
e. Plant Design SS Removal (%)
f. Plant Began Operation (year)
g. Plant Lai.t Major Revision (year)
DISCHARGE SERIAL NUMBER
211b
212.:.
21241
2131
213b
213a'
* 13A
2.131
213f
3, ASE, N, PG, FSR, Post
Aeration, DA, T, B
4.5
98
N/A
N/A
96
1962
1971
mgd
96
FOR AGENCY USE
1
11-4

DISCHAFGE SERIAL NUMBER
FOR AGENCY USE
14. Description of Influent and Effluent (see Instructions)
Parameter and Code
214 '
Influent
Effluent
Annual Average
I\)
Value
$o
El
c.
4
R 0
c a
C Q
a>
(2)
w Lowest Monthly
Average Value
Highest Monthly
.. Average Value
i Frequency of ,
Analysis
Number of
Analyses
Sample Type
l.l.►w
Million gallons per day
St)t151)
4.42
pll
t)iW0t)
xK
-l'nll%
Temperature (winter)
°F
741)2ii .
=
50° F
-
Temperature .;summer)
F
74027
r
68° F
-
,
Fecal Streptocucci Bacteria
Number/100 inl
74054
(Provide if available)
Fecal Coliform Bacteria
Number/100 ml
74055
(Provide if avaiiable)
.
Total Coliform Bacteria
Number/100 nil
74056
(Provide if available)
.,
.
BOD 5-day
mg/1
00310
250
5
Chemical Oxygen Demand (COD)
mg/1
00340
(Provide if available)
OR
Total Organic Carbon (TOC)
mg/1
00680
(Provide if available)
(Either analysis is acceptable)
750
15
—
—
Chlorine —Total Residual
mg/1
50060
_
_
11-5

DISCHARGE SERIAL NUMBER
14. Description of Influent and Effluent (see instructions) (Continued)
FOR AGENCY USE
Influent
Effluent
and Code
xv
x < }.
1
Q
1„;u
.;'f
a>
(1)
at
a
,'7
a>
(2)
o 'go
2 >
i g
a4
(3)
IIParameter
2 >
u
M
i4
(4)
c.4
�Q� ►
O7
it'
(5)
o
o Et.,
.�
z 4
(6)
H;
o.
n
(7)
Total Solids
l
005oo
os
< WOO
< M0000
Total Dissolved Solids
mg/I
70300
< 1000
< 1000
Total Suspended Solids
mg/1
00530
200
10
Settleable Matter (Residue )
ml/l
00545
—
—
Ammonia (as N)
mg/1
00610
(Provide if available)
25
2
Kjeldahl Nitrogen
mg/1
00625
(Provide if available)
37.5
3
Nitrate (as N)
mg/1
00620
(Provide if available)
_
—
Nitrite (as N)
mg/1
00615
(Provide if available)
—
—
•
Phosphorus Total (as P)
mg/I
00665
(Provide if available)
_
—
Dissolved Oxygen (DO)
mg/1
00300
6
II-6

DISCHARGE SERIAL. NUMBER
FOR AGENCY USE
IS. Additional Wastewater Characteristics
Check the box next to each parameter If It is present In the effluent. (sec instructions)
Parameter
(215) _
�
Parameter
(215)
c
Parameter
(215)
c
a.
Thallium
01059
Bromide
71870
Cobalt
01037
Chloride
00940
Chromium
01034
Titanium
01152
Cyanide
00720
Copper
01042
Tin
01102
Fluoride
00951
Iron
01045
Zinc
01092
Sulfide
00745
Lead
01051
Algicides*
74051
Aluminum
01105
Manganese
01055
Chlorinated organic compounds*
74052
Antimony
01097
Mercury
71900
Oil and grease
00550
Arsenic
01002
Molybdenum
01062
Pesticides*
74053
Beryllium
01012
Nickel
01067
Phenols
32730
Barium
01007
Selenium
01147
Surfactants
38260
Boron
01022
Silver
01077
Radioactivity*
74050
Cadmium
01027
*Provide specific compound and/or element in Item 17, if known.
Pesticides (Insecticides, fungicides, and rodenticides) must be repotted In terms of the acceptable common names specified in Acceptable Com-
mon Names and Chemical Names for the Ingredient Statement on Pesticide Labels, 2nd Edition, Environmental Protection Agency, Washington,
D.C. 20250, June 1972, as required by Subsection 162.7(b) of the Regulations for the Enforcement of the Federal Insecticide, Fungicide, and
Rodenticide Act.
No wastewater at present. Unable to supply specific information.
II-7

. .
• DISCHARGE SERIAL NUMBER
HI. Plant Controls Check If the follow-
ing plant controls are available
for this discharge
Alternate power source for major
pumping facility Including those
for collection system lift stations
Alarm for power or equipment
failure
17. Additional Information
0 APS
0 ALM
FOR AGENCY USE I
Item
Number
Information
11-8
*U. S. GOVERNMENT PRINTING OFFILE 1973 0 - 500.432

PUN "4,ACIN.Y UDC
STANDARD FORM A —MUNICIPAL
SECTION III. SCHEDULED IMPROVEMENTS AND SCHEDULES OF IMPLEMENTATION
This section requires Information on any uncompleted implementation schedule which has been Imposed for construction of waste treatment
facilities. Requirement schedules may have been established by locsl. State. or Federal agencies or by court action. IF YOU ARE SUBJECT TO
SEVERAL DIFFERENT IMPLEMENTATION $CHEDULEs. EITHER BECAUSE OF DIFFERENT LEVELS OF AUTHORITY IMPOSING
DIFFERENT SCHEDULES (ITEM lb) AND/OR STAGED CONSTRUCTION OF SEPARATE OPERATIONAL UNITS (ITEM lc), SUBMIT A
SEPARATE SECTION 111 FOR EACH ONE.
1. improvements Required
a. Discharge Serial Numbers
Affected List the discharge
serial numbers, assigned in Sec-
tion I1, that are covered by this
implementation schedule
b. Authority imposing Requirement
Check the appropriate item indi-
cating the authority for the Im-
plementation schedule If the
identical implementation sched-
ule has been ordered by more
than one authority, check the
appropriate Items. (see in-
structions)
Locally developed plan
Areawide Plan
Basin Plan
State approved implementation
schedule
Federal approved water quality
standards Implementation plan
Federal enforcement procedure
or action
State court order
Federal court order
001
❑ LOC
❑ ARE
p BAS
❑ SQS
[] WQS
❑ ENF
❑ CRT
O FED
FOR AGENCY USE
•
c. Improvement Description Specify the 3-character code for the
General Action Description In Table 11 that best describes the
Improvements required by the implementation schedule. If more
than one schedule applies to the facility because of a staged con-
struction schedule, state the stage of construction being described
here with the appropriate general action code. submit a separate
Section 111 for each stage of construction planned. Also, list all
the 3-character (Specific Action) codes which describe In more
detail the pollution abatement practices that the implementation
schedule requires.
>x.:.. 3-character general action MOD - Permit holder to change from 5tevcoknit fabrics to
:, < .:;•
description •' the Town of Wallace
•
3-character specific action `{'•
descriptions-•' / / / /
_. implementation Schedule and 3. Actual Completion Dates
Provide dates imposed by schedule and any actuai dates of completion for implementation steps
listed below. Indicate dates as accurately as possible. (see instructions)
Implementation Steps
a. Preliminary plan complete
b. Final plan complete
c. Financing complete & contract
awarded
d. Site acquired
e. Begin construction
f. End construction
g. Begin Discharge
h. Operational level attained
2. Schedule (Yr /Mo /Day)
3. Actual Completion (Yr /Mo /Day)
/ /
/ /
/ /
/ /
immediate
This section contains 1 page.
GPO 865.707

STANDARD FORM A —MUNICIPAL
FOR AGENCY USE I
.. I
SECTION W. INDUSTRIAL WASTE CONTRIBUTION TO MUNICIPAL SYSTEM
Submit a description of each major industrial facility discharging to the municipal system, using a separate Suction IV for each facility descrip-
tion. Indicate the 4 digit Standard Industrial Classification (SIC) Code for the industry, the major product or raw material. the flow (in thou-
sand gallons per day), and the characteristics of the wastewater discharged from the industrial facility into the municipal system. Consult Table
111 for standard neasures of products or raw materials. (see Instructions)
1.
Major Contrebuting Facility
(see instructions)
Name
Numbers. Street
City
County
State
Zip Code
2. Primary Standard industrial
Classification Coda (see
Instructions)
3. Principal Product or Raw
Material (see instructions)
Product
Raw Material
4. Flow Indicate the volume of water
discharged into the municipal sys-
tem in thousand .gallons per day
and whether this discharge is inter-
mittent or continuous.
3. Pretreatment Provided Indicate If
pretreatment is provided prior to
entering the municipal system
I. Characteristics of wastewater
(see instructions)
401e
40$b
401 a
401b
401c
401 d
401 e
4011
402
403a
403b
404a
404b
405
thousand gallons per day
❑ Intermittent (Int) Continuous (con)
❑ Yes No
Qusntlty
IMP
Units (See
Table III)
Parameter
Name
Parameter
Number
Value
No industrial contributions at this time. Industries are being
actively recruited.
Iv-1
GPO e65.706
This section contains l page.

ENGINEERING EVALUATION
WASTEWATER TREATMENT FACILITIES UTILIZATION
WALLACE, NORTH CAROLINA
August 1998
o<ss„ etio,
-�HCAR1%
•
;AO rs1 6/70t-
• SEAS, =
•
21 9792 O=
dj'�•F I. CH 14\v `%s
};4" it` gk
ee
m'§ Everette L. Chambliss, Jr.
THE WOOTEN COMPANY
CONSULTING ENGINEERS
120 North Boylan Avenue
Raleigh, North Carolina 27603

ENGINEERING EVALUATION
WASTEWATER TREATMENT FACILITIES UTILIZATION
WALLACE, NORTH CAROLINA
,,., August 1998
RIP
001111111,1111,
om,: SEAL /11(7111
G ; 9792 )42,q
;;41 gkete
Everette L. Chambliss, Jr.
r•
THE WOOTEN COMPANY
CONSULTING ENGINEERS
120 North Boylan Avenue
Raleigh, North Carolina 27603

PM
Table of Contents
pm PURPOSE OF STUDY 1
DESCRIPTION OF EXISTING FACILITIES 2
CAPACITY RATING OF EXISTING FACILITIES 6
'•,
UNDERLOADED OPERATIONAL PLAN 8
MODIFICATIONS REQUIRED FOR FULL DESIGN LOAD 11
mil SUMMARY AND PHASED IMPLEMENTATION PLAN 14

EMI
MI•
PURPOSE OF STUDY
Stevcoknit Fabrics, a textile dying and finishing operation, is closing down its operations in the
Town of Wallace. The industry has given to the Town not only the buildings that formerly housed
its manufacturing and warehousing operations, but also its wastewater treatment plant. The
wastewater treatment plant is an activated sludge plant with tertiary filters permitted at 5 MGD.
North Carolina Division of Water Quality (NC-DWQ) officials have stated that they will modify the
permit of the Stevcoknit Fabrics treatment plant so that the permit will be in the Town's name.
However, prior to modifying the permit for the treatment plant, the NC-DWQ will require that an
engineering evaluation be done for the plant. The purpose of that evaluation would to be to identify
the actual treatment capacity of the plant in terms of the type of waste the Town expects to receive
at the plant and to identify any improvements that may be necessary to operate the plant.
The Town of Wallace plans to use the former assets of Stevcoknit Fabrics to recruit new and
badly needed industrial development. However, it is not known at this time what types of
industries will be recruited, and what types of flow those industries may require. It is possible that
the former Stevcoknit Fabrics plant may have to be operated for an extended time period at
wastewater flow rates substantially below the actual capacity of the plant. NC-DWQ facilities have
also asked that an operational plan be developed for this underloaded situation as a part of the
engineering evaluation. Stevcokni . cs was operating its plant under an SOC that, among other
things, required that the dischar: pint o the plant be moved to a downstream location where there
would be greater flow to assimil..- • e wastewater discharge. NC-DWQ officials have stated that
they would expect the discharge point to be relocated with the transfer of the permit.
The purpose of this report is to establish an appropriate design capacity for the treatment plant
once its operation is assumed by the Town of Wallace, to present an operational plan for the plant
suitable for use in underloaded conditions, to identify any needed improvements to the plant,
including moving the plant discharge to a downstream location, and to project the construction
costs of any needed improvements. This report is intended to provide the technical support for an
application for a major modification to the NPDES Permit for the Stevcoknit Fabrics wastewater
treatment plant that will among other things name the Town of Wallace as the permits holder.

PIM
FRR
Poil
DESCRIPTION OF EXISTING FACILITIES
The existing 5.0tertiary wastewater treatment facility is a complete mix, extended aeration
activated sludge biological treatment process. The present facilities were apparently constructed in
four major construction phases. Facilities constructed in the first two phases have been modified in
subsequent phases to be compatible with later construction. The original activated sludge facility
was constructed to run the contact stabilization process. The rated treatment capacity of the old
facility is unknown. Based on construction plan di e ' . s, it likely had a treatment capacity of
about 0.5 MGD. The original facility was converted t • e complete mix, activated sludge process
in the 1970's when the plant was expanded to 5.0 MG 1 capacity. Operation of the original plant is
not in the current NPDES permit and the plant is not in service.
A 200-foot diameter extended aeration treatment facility was constructed as the second major
phase of construction. That facility was converted to a sludge digester at the time the plant
expansion to 5 MGD was constructed.
The final two phases of construction resulted in the 5.0 MGD capacity and the plant as it exists
now. The present plant consists of the following unit processes (Letters and numbers refer to the
identifiers shown on Figure 1, a flow schematic for the treatment plant):
21
Preliminary Treatment. (No screening or grit removal is provided).
Flow Equalization
A. Mixing Tank Provides Flow Equalization And Aeration
1. Main pump stations
Activated Sludge Systems
irculation and waste pumping.
Chlorination
Chlorine storage and feed system
D. Chlorine Contact Tank
Tertiary Filtration
E. Pressure Filters
F. Backwash Pump Station And Backwash Water Storage
3. Influent pump station
G. Post Aeration
�► H. Effluent Flow Measurement - Parshall Flume
2

AEI
Pitt
Bio-Solids Handling
I. Aerobic sludge digester
�► J. Sludge thickener (concentrator)
K . Sand drying beds
L. Acid Treatment Tanks
The capacities of the major unit processes are described as follows:
Flow Equalization
fun
MEI
0114
Number of tanks
Tank Volume
Full, gal
Minimum Water level, gal
Mechanical Aerators for Mixing and Aeration
Number of Aerators, ea.
Horsepower, ea.
Main Pumping Stations
From Equalization To Aeration Basins 1 & 2
3 identical pumps:
Capacity each:
Motor:
From Equalization to Aeration Basin 3
2 identical pumps:
Capacity each:
Motor:
Pumps Presently Not in service
Aeration Tanks
e ,,reetangu
e-ea
Mechanical Aerators, number per tank
Aerator horsepower, HP, ea.
Total Aeration Tank Volume, inccludin Eq tson, g
71JtAAQ
Hydraulic Retention Time at 5 MGD, hrs.
Clarifiers
Number ea.
Diameter, ft.
Sidewater, ft.
Capacity, each at 500 gal/day/sf, MGD
Clarifier overflow rate at 5 MGD, gal/day/sf
Sludge Recirculation Pumps
Number, ea.
Capacity, ea., gpm
Motor Horsepower
1
75 ,715,000 X 1
I 1,117,000
3
40
Gorman Rupp Model T8A-B
1,400 gpm @ 24 feet TDH
20 HP -
Gorman Rupp Model T6A-B
370 gpm @a 18 feet TDH
7.5 HP
Minimum
Chlorine Contact
Contact time exceeds 30 minutes at 5 MGD VNIATO
cet, c-i
ram► iLY��" 3
F1 PT
•
1,853,000
6
40
5,421,000
4,833,000
24
‘5"
566
3
1,050
20

l�l
Inn
Pressure Filters
Number, ea.
Total Surfa
Filter rate
Post Aeration
Volume, gal.
Hydraulic Retention Time MGD,, ' n.
Aeration Capacity:
Mechanical Aerators, ea.
Power, each HP
Sludge Management Facilities
a" Sludge Wasting from Return Sludge
Sludge Wasting Pumps
Number, ea.
�► Capacity, ea., gpm
Motor Horsepower
Sludge Thickener
Diameter, ft.
Drawoff Depth, ft.
Surface Area, ft2
Volume, gal.
Sludge Digester
Diameter, ft.
Sidewater Depth, ft.
Volume, MG
Sludge Drying Beds
Number, ea.
Surface Area, ea., sf
Total Surface Area, sf
Ian
Ongl
Peel
IP
-41 fipil.2-"r
Lit;‘,„ eei,(4'it(41
113c)�
1),?t ijcvis
(.
Sf�
G'
v
4
1,200
2.89
98,000
28
2
5
2
100
2
35
14
960
81,500
188
8
1.3 ✓
6
4,200
25,200

EXISTING PRIMARY FLOW THROUGH PLANT
8" INF. FROM MFG.`PLANT
\7 v`,,\ 4" SANITARY WASTE
it 30"w.CARTER PLANT DISCHARGE
,
\]I
INFLUENT
RAS
TOP 49.30
INV 42.00
46
PUMP STATION & ALTER BYPASS
INV 42.35
TOP 48.91
42
36
TOWN OF WALLACE 18" INTERCEPTOR
K
V p 54.5
AERATION BASIN
44.5
Li
K
_g 53.0
Lz
OA EQUALIZATION / AERATION
O AERATION BASINS
0 CLARIFIERS
O CHLORINE CONTACT
E PRESSURE FILTERS
F BACKWASH STORAGE
O POST AERATION
B3C3 ORIGINAL ACTIVATED SLUDGE PLANT
CAPACITY - 0.5 MGD
J.
K
L.
AEROBIC DIGESTOR FOR EXCESS SLUDGE
SLUDGE GRAVITY THICKENER
SLUDGE DRYING BEDS
ACID TREATMENT TANKS
® EFFLUENT FLOW MEASUREMENT AND DISCHARGE)
0 MAIN PUMP STATIONS
0 RETURN SLUDGE PUMP STATION
0 FILTER PUMP STATION
0
J
49.0
CHLORINE CONTACT
r \P\U41 He/
FIGURE 1
SCHEMATIC FLOW DIAGRAM
PRESSURE
FILTERS
3-40 HP 1800 GPM @ 60'
INV 45.0
0
0

01111
CAPACITY RATING OF EXISTING FACILITIES
NM The age of the existing plant exceeds the generally recognized useful life span for mechanical
equipment. However, high quality equipment was used in the plant and it remains in good
operating condition. When equipment is well maintained, useful life can exceed 40 years. Clarifier
oan
mechanisms have been replaced within the last year, and the pressure filters were all completely
rebuilt over within the last 5 years. Accordingly, age is not expected to adversely effect system
capacity.
The plant was not built as a municipal treatment system, and accordingly has two shortcomings
from the standpoint of a municipal plant:
• No fine screening or grit removal facilities are included. Stevcoknit has Iliad successful
operation without this preliminary equipment commonly provided at municipal wastewater
treatment plants.
• A non-standard electrical operating voltage is used at the plant. Motor control centers and all
motors in the plant are 550 volt, three phase, 60 cycle.
The plant has two other areas where improvements could be made. The clarifiers and aeration
basins are not interconnected, so if one aeration basin is taken out of service, one clarifier must
also be taken out of service. Similarly, if one clarifier is taken out of service, one aeration basin
must also be taken out of service. This limits operational flexibility. The aeration system for the
aerated bio-solids holding tank is inefficient, and could be improved. =_
The capacity of a wastewater treatment plant should be measured in terms of hydraulic capacity
and also in terms of the plant's ability to remove pollutants to meet its NPDES permit. Therefore,
the characteristics of the influent wastewater have a bearing on the plant's "capacity". A very high
strength wastewater may require pretreatment or reduction of the plant's rated hydraulic capacity.
The conventional approach for municipal plants is to design based on moderate strength domestic
wastewater and then require pretreatment by industries having wastewater which is stronger than
the municipal plant can treat. Alternately, the design hydraulic capacity of a plant can be reduced so
that it can safely handle a higher strength waste. Although it is common to refer to a plant as having
a capacity of some volume per day, in fact the actual capacity of a plant is determined by a number
of factors, of which flow is only one.
A unit process by unit process evaluation of
aeration capacity in the main plant treatment train
type wastewater having a BOD-5 of 250 mg/L
capacity would be adequate for treating nearl
th - . knit plant was undertaken. Installed
ower. Assuming typical municipal
onia level of 25 mg/L, this aeration
MGD o wastewater. The total aeration bast
0, u z.
..o
lr
r
yt,-<)(g.14)1,4;i
eligt(v
SIP
kojr-
�lY
d

AIM
holdin _ apacity, includin : , . within th equalization ,sin, uld provide a treatment volume of
gallo ypical municipal treatment plant aer- r on basins are sized to provide from 24
fam
to s detention tim ' . n basin capacity is sufficient for treating
domestic type waste in he 4.1 mgd to 5.2 range. Clarifiers are typically designed for a
Sri surface overflow rate of 450 g s ay sf or less on an average daily flow basis, which equates to a
peak loading rate of 1125 gal/day/sf. The Stevcoknit plant is equipped with an equalization basin,
which typically is not used on municipal type extended aeration plants. This equalization basin will
allow the peak loading on the clarifiers to be reduced, and accordingly a higher average daily
loading can be safely considered. It is recommended that the clarifier loading rate be limited to 50
fan
gal/day/sf of surface area on an average daily basis. This would result in a capacity rating
MGD. The existing facility should be capable of operating well within its permit limits at t
day average flow rate. Wastewater filtration rates for domestic wastewater are typically held to 2 to
4 gpm per square foot. Pressure filters like those installed at the Stevcoknit plant are rarely used in
fi" municipal practice. Pressure filters can handle a higher hydraulic load, so using the upper 4 gpm
per square foot design rate the tertiary filters should be adequate for 6.9 MGD. The most limiting
component of the existing plant therefore appears to be the clarifiers, and the capacity of the plant
when treating municipal type wastewater is 4.42 MGD. Many industrial wastewaters are treated as
easily, and sometimes more easily, than municipal type wastewater, and the large (600 HP)
c
aeration capacity installed at the plant would allow it to potentially treat 4.42 MGD of wastewater
much stronger than domestic strength. However, other types of industrial wastewaters are more
resistant to treatment than typical municipal wastewaters, and the capacity of the plant to treat these
type wastes could be less than 4.42 MGD. It is therefore recommended that the Town seek to have
the plant permitted as a 4.42 MGD facility, but that it evaluate each proposed industrial waste
carefully and recognize that depending on the type of industries it recruits it may or may not be able
0.1 to fully utilize the 4.42 mgd nominal capacity of the facility.

•
UNDERLOADED OPERATIONAL PLAN
The Town of Wallace operates an advanced wastewater treatment system on its own, and the
Stevcoknit plant will be the second treatment facility to be operated by the Town. Depending on the
growth within the Town and its service area, and particularly the growth in its wet industrial base,
it could be some time before the loading on the Stevcoknit plant approaches the 4.42 MGD capacity
of the plant. Ideally, the Town will soon succeed in recruiting an industrial base large enough to
load the plant to a level at least equivalent to 0.900 MGD of domestic wastewater. At this operating
load the hydraulic retention time with only one aeration basin would 48 hours. Operating the plant
aim with a low mixed liquor of suspended solids level (1000 mg/L ±) would allow for stable operation
at a 0.900 MGD flow rate with domestic type wastewater, and aerators could be controlled by time
clocks to provide adequate aeration without excessive energy costs. Operating such a large plant
with a lessor flow or waste load would present some operating challenges. An operational plan has
been prepared to address those challenges. The plan will allow the plant to operate at flows as low
as 0.250 MGD, should such a low flow operating condition prove necessary. It is suggested that
no attempt be made to operate the plant at flows less than 0.250 MGD unless high strength wastes
are involved.
In order to operate at extremely underloaded conditions with a reasonable per gallon treatment
cost, some physical modifications must be made to the treatment plant.These modifications would
be required to operate the plant when loaded with the equivalent of from 0.250 MGD to 0.900
MGD of domestic strength wastewater. The most expensive component to operate are the aeration
basins. In order to hold operating costs to manageable levels when treating low flows, minor
piping modifications can be made to allow taking the two aeration basins out of service (along with
twelve 40 HP aerators) and to allow use of the e utilization basiri an three 40 HP tie tors for
treatment of up to 1 to 1.5 MGD of wastewater, depending on wastewater strength. As flow
increases above the 0.500 MGD level, it may be necessary to relocate one or more aerators from
the aeration basin to the equalization basin, again depending on wastewater strength. One of the
two clarifiers would be used. The overflow rate would be so low that it would be likely that the
tertiary filters would not be required to remain within permit limits. The gravity bypass around the
0.4 pressure filters would allow leaving the filter influent pump station off line. Wastewater could
diverted to the plant from the Town collection system if needed to reach the minimum 0.250 MGD
.a treatment flow. In order to accomplish this diversion, the bottom elevation of the equalization bas j
would need to be lowered 4 feet. This will allow flow from the Town outfall line that passe
am through the treatment plant to enter the equalization basin by gravity. It isalsosuggested that a fin:
3.4FfP L f\io Gc �� -z�_ �j�t`'z1 I� /( 10f.Ti9 Iv4�i1),
OM ' N
/ r ‘....4-‘....4-
W4> f/7c 5� *a -`(1---6--/-5 7
?
j75 1 ov" r�tC 40 ru
lire► $, iivie�� �� ~ i ( 1 s eE� .a'af f''+! ‘

116'
FIGURE 2
MODIFICATION OF EXISTING EQUALIZATION BASIN AND
CONNECTION TO TOWN OF WALLACE OUTFALL LINE
8" INF. FROM MFG. PLANT
4" SANITARY WASTE
30"CARTER PLANT DISCHARGE
EQUALIZATION
BASIN
AERATION BASIN #1
12" RAS
AERATION BASIN #2
NEW SCREENING EXISTING 12" DIP ALTERNATE
18"
Town of Wallace 18" Outfall Line
DIVERSION BOX Incert Out EL 42
PLAN VIEW
260'
80'
224'
A
212'
68'
NEW BOTTOM
EXISTING BOTTOM
EL 42'
4.5'
L 39' ""EQUALIZATION STORAGE POOL
EL 36' EXISTING BOTTOM
4.5'
EL 32' NEW BOTTOM
6'
DETAIL OF EQUALIZATION BASIN MODIFICATION

screen be installed in the gravity line connecting the Town outfall line to the equalization basin.
Figure 2 is a schematic representation of how this would be accomplished. The existing pumps
now designed to lift wastewater from the equalization basin to the aeration basin would be
modified to discharge to the clarifiers. The pumps would be slowed and throttled to a reduced
�°► output rate closer to the actual expected flow. These modifications could not be completed without
incurring some expense. The expected cost for the modifications is projected as follows:
Oft
Modifications to Existing Equalization Basin
Lift Pump & Piping Modification
18" Influent Line
m, Influent Fine Screening & Compactor
Diversion Box
Electrical
Sitework &Misc
Sub -Total - Construction
Engineering
Contingency
Legal & Administrative
Total Projected Costs
The above costs would be in addition to the cost of relocating the discharge pipe
discussed in the following section.
r
NO
$140,000
6,000
8,000
90,000
10,000
10,000
46,000
$310,000
46,500
46,500
6.000
$409,000
for the facility
It is suggested that those components which are removed from service because of low loading
be filled with treated effluent and all equipment be exercised weekly. This will assure continued
availability of vital equipment and that the full capacity of the plant is ready for service whenever
needed.
:e7
off- `aY`�� �
�► 10

nr+
MODIFICATIONS REQUIRED FOR FULL DESIGN LOAD
North Carolina Division of Water Quality officials have stated that the discharge point will have
to be relocated as a condition of the Town of Wallace receiving a discharge permit for the plant.
Other modifications may also be needed if the facility is to treat both domestic and industrial
wastewater, and if it is to serve wastewaters originating at locations other than the former
Stevcoknit manufacturing and warehousing facilities. A connection with the existing Town outfall
line (that line actually runs through the Stevcoknit treatment plant site) would enable the plant to not
only serve the complex of facilities that was formerly the Stevcoknit manufacturing and
warehousing plant but to also serve industrial, commercial, and residential developments upstream
of the former Stevcoknit wastewater treatment plant. This would broaden the over all utility of the
treatment plant. Certain types of industrial process wastewaters, including many textile dying and
finishing wastes, are more easily treated when mixed with domestic type wastes. Therefore,
connection of the plant to the existing Town of Wallace outfall system could also potentially
increase the plant utility as an industrial treatment facility. Connection to the Wallace collection
system would, however, make it advisable to construct screening and grit removal facilities at the
front end of the plant. If only a small amount of flow were to be diverted from the Wallace system,
grit removal facilities would not be essential, but the more flow received from the Wallace
�► collection system, the greater would be the need for grit removal.
The cost for relocating the outfall line of the former Stevcoknit plant has been projected by
Century/ von Oesen firm in a report dated May 1997 and titled "Preliminary Engineering Report,
Stevcoknit/Wallace Interconnection, Wallace, North Carolina." Those construction costs are
restated as follows:
am
24"PVC outfall
0-4 feet deep 20351f @ $52.00/lf $105,820
am 4-6 feet deep 14721f @ $57.00/lf 83,904
6-8 feet deep 11181f @ $67.00/lf 74,906
8-10 feet deep 8831f @ $77.00/lf 67,991
aft 10-12 feet deep 2951f @ $87.00/lf 25,665
24" DI outfall 11001f @ $80.00/lf 88,000
Manholes
am 0-4 feet deep 8 ea @ $1400/ea 11,200
4-6 feet deep 6 ea @ $1600/ea 9,600
6-8 feet deep 4 ea @ $1800/ea 7,200
8-10 feet deep 3 ea @ $2200/ea 6,600
°" 10-12 feet deep 1 ea @ $2300/ea 2,300
Drop Manholes
8-10 feet deep 1 ea @ $2500/ea 2,500
aa 10-12 feet deep 1 ea @ 2600/ea 2,600
Bore & Jack 24" PVC 60 if @ $75.00/lf 4,500
1,
ragl

A�1
Bore & Jack 36" casing 601f @a $230.00/lf
Discharge Structure 1 ea @ $3,000
Asphalt Drive Repair 50 sy @a $30.00/sy
Clearing & Grubbing 6000 if a@ $3.00/lf
Sub -Total Construction (per Century/ von Oesen report)
Survey (per Century/ von Oesen report)
Engineering
Contingency
Legal & administrative
Total Projected Cost
13,800
3,000
1,500
18.000
$529,086
$10,000
79,157
79,157
10.600
$708,000
The Century/ von Oesen report also called for connecting the Stevcoknit treatment plant to the
Town sewer collection system by means of a small lift station with a coarse screening and grit
removal unit. Century/von Oesen envisioned only a maximum of 250,000 gallons per day of
municipal wastewater being transferred. At the time the Century/ von Oesen report was prepared, it
was assumed that Stevcoknit would continue in operation, and the purpose of the transfer was to
improve the treatability of the Stevcoknit wastewater while relieving some of the load on the Town
of Wallace plant. Now that Stevcoknit has closed its operation, it is suggested that the connection
be designed for a larger flow transfer increment. Using a larger flow transfer incremenx makes it
logical to provide larger and better screening, and larger and better grit removal than was proposed
by Century/von Oesen. A gravity connection, rather than a pumped connection, can be made by
lowering the bottom of the equalization basin and changing the operating levels in the basin. The
cost of this work could vary depending on the design flow of the screening and grit removal
facilities, i.e. how much of the 4.42 MGD design flow is expected to originate within the Town of
Wallace service area, as opposed to how much is expected to originate from new industries
locating in the old Stevcoknit buildings. A diversion of 1.5 MGD is assumed in pro 'e ' its
for planning purposes. The costs of constructing the facilities needed to divert up 1.5 MG-
flow from within the Town of Wallace collection system to the former Stevcoknit treatment plant is
projected as follows:
Modifications to Existing Equalization Basin
18" Influent Line
Influent Fine Screening & Compactor
Aerated Grit Removal
Diversion Box
Electrical
Sitework &Misc
Sub -Total - Construction
Engineering
Contingency
12
$140,000
8,000
90,000
120,000
10,000 ,
21,000 j
55.000 .
Loy
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$444,000 f,
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$53,500 I U I
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Legal & Administrative 9,000
Total Projected Costs $573,000
In addition to the above modifications, it would also be in the best interest of the Town of
Wallace to construct the improvements needed to increase the operational flexibility of the clarifiers
and aeration basin and the efficiency of the aerobic sludge digestion/bio-solids holding tank.
Operational flexibility would be increased by constructing a weir box into which the effluent from
both aeration basins would be rerouted, and through which both clarifiers would be fed. Such
improvements could be constructed for a projected cost of $220,000. The aerobic sludge
digestion/bio-solids holding tank efficiency could be improved by replacing the present system of 4
positive displacement blowers each discharging through a separate diffuser system. The type of
replacement system chosen would depend on the type of wastewater the plant is expected to
receive. If the plant is expected to treat predominately textile wastes with high lint loads, a jet
aeration system with aspirating type jets is recommended. If the wastewater is expected to be
'"' largely lint free, then floating aerators could be effectively employed at a lessor cost. The projected
cost of an aspirating jet aeration system is $290,000. The projected cost of a mechanical aeration
system is $155,000.
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SUMMARY AND PHASED IMPLEMENTATION PLAN
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acquisition will not be "free". Considering the size of the plant clarifiers, it is suggested that the
permitted plant capacity be reduced to 4.42 MGD. North Carolina Division of Water Quality
officials have stated that even with a reduced permitted flow, the discharge point of the plant will
still need to be moved. The projected cost for this movement is $708,000. Therefore, the Town of
Wallace can expect to have to spend at least $708,000 to accept the plant. After the initial
expenditure of $708,000, the monies the Town will have to spend will depend to a large degree on
how the plant is utilized.
The acquisition of the Stevcoknit Fabrics wastewater treatment plant by the Town of Wallace
represents the acquisition of a potentially valuable asset. Construction of a new plant of comparable
capacity and treatment capability could easily cost in the 16 to 20 million dollar range. However, its
Should the Town locate an industry with wastewater similar to that of Stevcoknit, both in terms
of quantity and quality, little in the way of additional capital expenditures would be required.
Expenditures of $220,000 to increase the flexibility of operation for the aeration basin and clarifiers
would be desirable, but only if wastewater flows were expected to exceed 2.2 MGD. At flows less
than 2.2 MGD, the limitations of the existing system arrangement, (in which each aeration basin is
paired with one clarifier, and both aeration basin and clarifier must be taken out of service if either
the aeration basin or its paired clarifier need to be taken out of service for any reason), do not
present any real threat to plant reliability. Aerobic digestion improvements costing from $15 , 00
to $290,000, depending on the type of wastewater expected at the plant, are also desirable. Again,
however, these improvements would not be needed if the plant will only be half loaded.
Should expected wastewater flows be less than 1 MGD, it would be best to modify the plant to
use what is now the equalization basin as an aeration basin, and to by-pass and not use the existing
aeration basins until flows reach the 1.0 to 1.5 MGD range. It is not recommended that the plant be
operated at a flow less than 0.250 MGD, unless the wastewater pollutant strength is at least equal
to that expected from 0.250 MGD of domestic type wastewater. If need be the plant can be
modified to accept some domestic wastewater so that the load to the plant will be at least 0.250
MGD. Wastewater from the Wallace collection system could be diverted to the industrial
wastewater treatment plant to provided the minimum required volume. The diversion would require
modifying the existing equalization basin, installing a screen for the domestic wastes, and
miscellaneous pump and piping modifications. These modifications could be completed for a
projected cost of $409,000. More elaborate modifications would be required if the plant is expected
g" to take a larger percentage of its total flow from the Town of Wallace collection system. The nature
14

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of these modifications would depend on just how much flow was to be diverted from the collection
system. Costs were projected as being $573,000 for building the facilities necessary for diverting
as much as 1.5 MGD from the Wallace collection system to the former Stevcoknit treatment plant.
It is possible that there will be an extended time period in which no wastewater flow will be
discharged to the former Stevcoknit plant. Under these circumstances it is recommended that the
Town fill all the major treatment units with water, and operate all mechanical equipment a few
hours per week. Mechanical equipment should also be kept lubricated in accordance with
manufacturers recommendations, and lubricants should be changed in accordance with
manufacturers recommendations. These arrangements will guard against equipment "freezing up"
from disuse, while allowing the Town to show prospective users a treatment plant ready to operate
the day the industries locate at the Town.
In summary, the Town must expect to spend $708,000 in relocating the discharge point of the
former Stevcoknit wastewater treatment plant. Other expenditures may or may not be required,
depending on what types of uses for the plant ultimately develop. Aggregate additional expenses in
excess of $1 million are not inconceivable, but costs of such a magnitude would only be advisable
if relatively large wastewater flows are expected, with a large portion of the flows originating from
some location other than the former Stevcoknit manufacturing plant complex.
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