NC0043320_Permit Issuance_20040809

WATFRpG
7
Michael F. Easley, Governor
State of North Carolina
William G. Ross, Jr., Secretary
Department of Environment and Natural Resources
0 Alan W. Klimek, P.E., Director
Division of Water Duality
August 9, 2004
Mr. Paul Smart
Burlington Industries
740 Cheraw Highway
Cordova, North Carolina 28376
Subject: Issuance of NPDES Permit
NCO043320
Burlington Industries WWTP
Richmond County
Dear Mr. Smart:
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 no major changes from the draft permit sent to you on June 9, 2004.
This permit includes a TRC limit that will take effect on March 1, 2006. If you wish to install
dechlorination equipment, the Division has promulgated a simplified approval process for such projects.
Guidance for approval of dechlorination projects is attached.
If any parts, measurement frequencies or sampling requirements contained in this permit are
unacceptable to you, you have the right to an adjudicatory hearing upon written request within thirty
(30) days following receipt of this letter. This request must be in the form of a written petition,
conforming to Chapter 150B of the North Carolina General Statutes, and filed with the Office of
Administrative Hearings (6714 Mail Service Center, Raleigh, North Carolina 27699-6714). Unless such
demand is made, this decision shall be final and binding.
Please note that this permit is not transferable except after notice to the Division. The Division
may require modification or revocation and reissuance of the permit. This permit does not affect the
legal requirements to obtain other permits which may be required by the Division of Water Quality or
permits required by the Division of Land Resources, the Coastal Area Management Act or any other
Federal or Local governmental permit that may be required. If you Have any questions concerning this
permit, please contact Toya Fields at telephone number [phone], extension 551.
Sincerely,
ORIGINAL SIGNED BY
y. Tom Belnick
Alan W. Klimek, P.E.
cc: Central Files
Fayetteville Regional Office/Water Quality Section
EPA, Region 4
NPDES Unit
North Carolina Division of Water Quality [phone]
1617 Mail Service Center FAX [phone]
Raleigh, North Carolina 27699-1617 On the Internet at http://h2o.mr.state.nc.us/

4 6.
Permit # NCO043320
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,
Burlington Industries, Incorporated
is hereby authorized to discharge wastewater from a facility located at the
Richmond Plant
Old Cheraw Highway
Cordova
Richmond County
to receiving waters designated as Hitchcock Creek in the Yadkin -Pee Dee 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 September 1, 2004.
This permit and authorization to discharge shall expire at midnight on February 28,
2009.
Signed this day August 9, 2004.
ORIGINAL SIGNED BY
Tom BeInick
Alan W. Klimek, P.E. Director
Division of Water Quality
By Authority of the Environmental Management Commission

Permit # NC0043320
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.
Burlington Industries, Inc. is hereby authorized to:
1. Continue operation of a 1.2 MGD wastewater treatment facility consisting of the
following components:
• Two aeration basins in parallel
• Two clarifiers in parallel
• Disinfection facilities
• Aerobic sludge digestion and sludge drying beds
The facility is located at the Richmond Plant, on Old Cheraw Highway at the
junction of NCSR 1103 and NCSR 1109 in Cordova, Richmond County.
2. Discharge from said treatment works (outfall 001) and cooling water (outfall 002)
at the location specified on the attached map into Hitchcock Creek, a class C
water in the Yadkin -Pee Dee River Basin.

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(001, 002)
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Burlington Industries WWTP — NCO04332
Quad Name: Rockingham
ing Stream: Hitchcock Creek
i Class: C
sin: Yadkin -Pee Dee 03-07-16

-9 ,. 1
Permit #NC0043320
A (1). EFFLUENT LIMITATIONS AND MONITORING REQUIREMENTS
During the period beginning on the effective date of this 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:
EFFLUENT
.CHARACTERISTICS
d$t-HARGE LIMITATIONS
MONITORING REQUIIWM�NTS
i lti1
Daily Maximum
Measurement
Frequency
Sample
Type
S��p
Flow
1.2 MGD
[1b
Continuous
Recording
I or E
BODs, 20oC
30
/da
43.0
m/L
836
lbs/da
83.6
m /L
Weekly
Composite
E
TSS
761bs/da
810lbs/da
Weekl
Com osite
E
NH3-N
50
/da
5.0
m /L
250
lbs/da
25.0
m /L
Weekly
Composite
E
Fecal Coliform
(geometric mean)
200/100 ml
400/100 ml
Weekly'
Grab
E
Total Residual Chlorine2
28.0 µ /L
3/Week
Grab
E
COD
1772 lbs/day
2828lbs/day
Weekly
Composite
E
Total Nitrogen
(NO2 + NO3 +TKN)
Monthly
Composite
E
Total Phosphorus
Monthly
Composite
E
Dissolved Oxygen3
3/Week'
Grab
E,U,D
Conductivity
3/Week'
Grab
E,U,D
Chronic Toxicity4
Quarterly
Composite
E
H
Between 6.0 and 9.0 s.u.
3/Week
Grab
E
Temperature
3/Week'
Grab
E,U,D
Total Copper
Monthly
Composite
E
Fluoride
Quarterly
Composite
E
Chloride
Quarterly
Composite
E
Total Zinc
Monthly
Composite
E
THERE SHALL BE NO DISCHARGE OF FLOATING SOLIDS OR FOAM VISIBLE IN OTHER
THAN TRACE AMOUNTS.
NoTEs:
1. Sample Locations: I — Intake, E — Effluent, U — Upstream above the discharge, D — Downstream
approximately 3/4 of a mile below the discharge. Instream samples shall be grab samples. Instream samples
for dissolved oxygen, conductivity, and temperature shall be collected three times per week during the
months of June, July, August, and September and weekly during the remainder of the year. Burlington
Industries WWTP is a participant of the Yadkin Pee -Dee River Basin Association and thus instream
monitoring requirements as specified in this permit are waived. Should Burlington Industries'
membership in the association be terminated, the instream monitoring requirements will be reinstated.
2. Limit takes effect March 1, 2006. Limit and monitoring requirement apply only if chlorine is used for
disinfection.
3. The daily average dissolved oxygen concentration in the effluent shall not be less than 5.0 mg/L.
4. Chronic Toxicity (Ceriodaphnia) P/F @ 7.0%; February, May, August, and November. See Condition A(3)
of this permit.

I !,
Permit #NC0043320
A (2). EFFLUENT LIMITATIONS AND MONITORING REQUIREMENTS
During the period beginning upon the effective date of this permit and lasting until expiration, the
Permittee is authorized to discharge from outfall(s) serial number 002-Cooling Water. Such
discharges shall be limited and monitored by the Permittee as specified below:
EFFLUENT
'CHARACTERISTICS
I ISCHARGE
LIMITATIONS
'PORING REQUIREMENTS
_
Monthly
Average
Daily.
Maximum
Sample Type
Sample .
Locationi
Flow (MGD)
Monthly
Instantaneous
E
Temperature
See Note 2
See Note 2
Monthly
Grab
E,U,D
Total Residual Ch1orine3
28 µ /L
MonthlyGrab
E
H
Between 6.0 and 9.0 s.u.
Monthly
Grab
E
THERE SHALL BE NO DISCHARGE OF FLOATING SOLIDS OR VISIBLE FOAM IN OTHER THAN TRACE
AMOUNTS.
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 AUTHORIZATION FROM THE DIVISION OF WATER QUALITY
PRIOR TO UTILIIZING ANY BIOCIDE IN THE COOLING WATER; SEE CONDITION A(4) OF THIS
PERMIT.
Notes:
I. Sample Locations: E —Effluent, U —Upstream, D — Downstream
2. The temperature of the effluent shall as not to cause an increase in the temperature of the receiving
stream of more than 2.80C and in no case cause the ambient water temperature to exceed 32.00C.
3. Limit and monitoring requirement only apply if chlorine or chlorine derivative is added to the
cooling water. Limit takes effect March 1, 2006.

Permit #NC0043320
SUPPLEMENT TO EFFLUENT LIMITATIONS
AND MONITORING REQUIREMENTS
SPECIAL CONDITIONS
A(3). CHRONIC TOXICITY PERMIT LIMIT (QRTRLY)
The effluent discharge shall at no time exhibit observable inhibition of reproduction or significant mortality to
Ceriodaphnia dubia at an effluent concentration of 7%.
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 nionths of February, May, August and November. Effluent sampling
for this testing shall be performed at the NPDES permitted final effluent discharge below all treatment processes.
If the test procedure performed as the first test of any single quarter results in a failure or ChV below the permit limit,
then multiple -concentration testing shall be performed at a minimum, in each of the two following months as described
in "North Carolina Phase II Chronic Whole Effluent Toxicity Test Procedure" (Revised -February 1998) or subsequent
versions.
The chronic value for multiple concentration tests will be determined using the geometric mean of the highest
concentration having no detectable impairment of reproduction or survival and the lowest concentration that does have
a detectable impairment of reproduction or survival. The definition of "detectable impairment," collection methods,
exposure regimes, and further statistical methods are specified in the "North Carolina Phase II Chronic Whole Effluent
Toxicity Test Procedure" (Revised -February 1998) or subsequent versions.
All toxicity testing results required as part of this permit condition will be entered on the Effluent Discharge
Monitoring Form (MR-1) for the months in which tests were performed, using the parameter code TGP3B for the
pass/fail results and TI-IP3B for the Chronic Value. Additionally, DWQ Form AT-3 (original) is to be sent to the
following address:
Attention: NC DENR / DWQ / Environmental Sciences Branch
1621 Mail Service Center
Raleigh, North Carolina 27699-1621
Completed Aquatic Toxicity Test Forms shall be filed with the Environmental Sciences Branch no later than 30 days
after the end of the reporting period for which the report is made.
Test data shall be complete, accurate, include all supporting chemical/physical measurements and all
concentration/response data, and be certified by laboratory supervisor and ORC or approved designate signature. Total
residual chlorine of the effluent toxicity sample must be measured and reported if chlorine is employed for disinfection
of the waste stream.
Should there be no discharge of flow from the facility during a month in which toxicity monitoring is required, the
permittee will complete the information located at the top of the aquatic toxicity (AT) test form indicating the facility
name, permit number, pipe number, county, and the month/year of the report with the notation of "No Flow" in the
comment area of the form. The report shall be submitted to the Environmental Sciences Branch at the address cited
above.
Should the permittee fail to monitor during a month in which toxicity monitoring is required, monitoring will be
required during the following month.
Should any test data from this monitoring requirement or tests performed by the North Carolina Division of Water
Quality indicate potential impacts to the receiving stream, this permit may be re -opened and modified to include
alternate monitoring requirements or limits.
NOTE: Failure to achieve test conditions as specified in the cited document, such as minimum control organism
survival, minimum control organism reproduction, and appropriate environmental controls, shall constitute an invalid
test and will require immediate follow-up testing to be completed no later than the last day of the month following the
month of the initial monitoring.

r t,
Permit # NC0043320
SUPPLEMENT TO EFFLUENT LIMITATIONS
AND MONITORING REQUIREMENTS
SPECIAL CONDITIONS- continued
A (4). BIOCIDE CONDITION
The permittee shall not use any biocides except those approved in conjunction with the permit application. The
permittee shall notify the Director in writing not later than ninety (90) days prior to instituting use of any additional
biocide used in cooling systems which may be toxic to aquatic life other than those previously reported to the Division
of Water Quality. Such notification shall include completion of Biocide Worksheet Form 101 and a map locating the
discharge point and receiving stream.

J��'Eo SrATFs.
A UNITED STATES ENVIRONMENTAL PROTECTION AGENCY
�m >W REGION 4
ATLANTA FEDERAL CENTER
Z;Fti�1r1o2 61 FORSYTH STREET
r�( PROSES ATLANTA, GEORGIA 30303-8960
JUN 1 6 2004
Ms. LeToya Fields
North Carolina Department of Environment and
Natural Resources
Division of Water Quality
NPDES Unit
1617 Mail Service Center
Raleigh, INC 27699-1617
SUBJ: Draft NPDES Permit
Burlington Industries - Richmond Plant
Permit No. NCO043320
Dear Ms. Fields:
JUN 2 1 2004
nRiR - WATER OUALITy
In accordance with the EPA/NCDENR MOA, we have completed review of the draft permit
referenced above and have no comments. We request that we be afforded an additional review
opportunity only if significant changes are made to the draft permit prior to issuance or if significant
comments objecting to it are received. Otherwise, please send us one copy of the final permit when
issued.
Sincerely,
Marshall Hyatt, Environmental Scientist
Permits, Grants, and Technical Assistance Branch
Water Management Division
Internet Address (URL) • http://www.apa.gov
Recycled/Recyclable . Pdnled wRh vegetable Oil Based Inks on Recycled Paper (Minimum 30% Postconsumer)

Draft Permit Reviews (2)
A A
Subject: Draft Permit Reviews (2)
From: John Giorgino <[e-mail]>
Date: Tue, 15 Jun 2004 16:06:41 -0400
To: Toya Fields <[e-mail]>
Hi Toya, I have reviewed the following:
VEM43320 - Burlington Industries r
NCO041408 - Anson County WWTP
2 have no comments on the tox sections. Thanks for forwarding them.
-John
John Giorgino
Environmental Biologist
North Carolina Division of Water Quality
Aquatic Toxicology Unit
Mailing Address:
1621 MSC
Raleigh, NC 27699-1621
Office: 919 733-2136
Fax: [phone]
Email: [e-mail]
Web Page: http://www.esb.enr.state.nc.us
1 of 1 6/ 15/2004 4:16 PM

:ombined Invoice / Statement & Certified Affidavit
RICHMOND COUNTY DAILY JOURNAL
105 E. Washington Street • P.O. Box 1888
Rockingham, NC 28380
PHONE [phone] • FAX [phone]
Federal ID No. 58 2303137
NCDENR/DWQ/BUDGET OFFICE
CAROLYN BRYANT
1617 MAIL SERVICE CENTER
RALEIGH NC 27699-1617
STATE OF NORTH CAROLINA
COUNTY OF RICHMOND
Amount of Bill $ 88.50
IrI [s N.. W
'I
5 2004 J
1, Rick Bacon, Publisher of the
RICHMOND COUNTY DAILY JOURNAL
a newspaper published in Richmond County, NC
certify that the annexed advertisment of
BURLINGTON
was duly published in the aforesaid newspaper
1 time(s) for consecutive weeks
beginning with issue dated June 12 2004
(Signed)��ti�
Richmond County Daily Journal
Sworn to and subscribed before me, a Notary Public,
this day of June 12 20 4
(Signed., q
My Commission expires
Date JUne 12 2004
PLEASE PAY THIS AMOUNT $ 88.50
Terms: Net Due receipt of this Invoice
For proper credit, please enclose duplicate invoice with remittance
IMPORTANT: Please retain this affidavit for your records for legal reasons.
PUBLIC NOTICE
STATE OF NORTH CAROLINA
ENVIRONMENTAL MANAGEMENT
COMMISSIOWNPDES UNIT
1617 MAIL SERVICE CENTER
RALEIGH, NC 27699-1617
NOTIFICATION OF INTENT
TO ISSUE A
NPDES WASTEWATER PERMIT
On the basis of thorough staff re-
view and application of NC General
Statute 143.21, Public law 92-500 and
other lawful standards and regula-
lions, the North Carolina Environmen-
tal Management Commission propos-
es to issue a National Pollutant Dis-
charge Elimination System (NPDES)
wastewater discharge permit to the
person(s) listed below effective 45
days from the publish date of this no-
tice.
Written comments regarding the
proposed permit will be accepted until
30 days after the publish date of this
notice. All comments received prior to
that date are considered in the final
determinations regarding the proposal
permit. The Director of the NC Divi-
sion of Water Quality may decide to
hold a public meeting for the pro-
posed permit should the Division re-
ceive a significant degree of public in-
terest.
Copies of the draft permit and
other supporting information on file
used to determine conditions present
in the draft permit are available upon
request and payment of the cost of re-
production. Mail comments and/or re-
quest for information to the NC Divi-
sion of Water Quality at the above ad-
dress or call Ms. Carolyn Bryant at
919.733-5083. extension 520. Please
include the NPDES permit number
(attached) in any communication. In-
terested persons may also visit the Di-
vision of Water Quality at 512 N. Sal-
isbury Street, Raleigh, NC 27604-
1148 between the hours of 8:30 a.m.
and 5:00 p.m. to review information
on file.
Burlington Industries (740 Cher-
aw Highway, Cordova, NC 28376)
has applied for renewal of NPDES
permit NCO043320 for the Burlington
Industries/Richmond WWTP in Rich-
mond County. This permitted facility
discharges 1.2 MGD of treated waste-
water to Hitchcock Creek in the Yakin-
Pee Dee River Basin. Currently BOD,
ammonia nitrogen, fecal coliform and
total residual chlorine are water quali-
ty limited. This discharge may affect
future allocations in this portion of the
Yadkin -Pee Dee River Basin.
Jun12,2004

NCDENR / DWQ
FACT SHEET FOR NPDES PERMIT DEVELOPMENT
NPDES No. NCO043320
Burlington Industries
Faci1_ �nfornaton ,.
(1.) Facility Name:
Burlington Industries, Richmond Plant
(2.) Permitted Flow (MGD):
1 1.2 MGD (6.) County:
Richmond
(3.) Facili y Class:
Ill (7.) Regional Office:
Fayetteville
(4.) Pretreatment Program
N/A (8.) USGS To_ o Quad:_
' Rockingham
(5.) Permit Status:
—�
:Renewal (9.) USGS Quad Name:
j H19NE
w
= = -
� �
S aia exxs cs
(1.) Receiving Stream:
Creek (7.)_Drainage Area (mil) 134
......... ....
(2.) Sub -basin:
.Hitchcock ��—�
03-07-16 (8.) Summer 7Q10 (cfs):
W
25
— _.
(3.) Stream Index Number:
.__ _. _ _...._......._.__.._.._..._..._.._-....___..._.._...._._..____..
13-39-(10) b (9.) Winter 7Q10 (cfs):
; 68
(4.) Stream Classification:
_._.....__...._._......__._......._._..._...._.._._.__._.._._........_._...____._.-_............_.........._.-_r.._.._._...._
C ! (10.) 30Q2 (cfs):
.. _------_.__.-.__._____..__._._.___.__-_._._.........._._._..___.__..___...........-----_-._...._....._._.._.....___......._......_._...._
__.__._...._...._.__...........__-_................___
(5.) 303(d) Status:
:Listed; fecal, pH, (11.) Average Flow (cfs):
1174
__.__.-._-._._._..._._...._..__
sediment 1
_
3
(6.) 305(b) Status:
(12.) IWC %:
1.0 Proposed Changes Incorporated into Permit Renewal
Add daily maximum ammonia limit -
Add TRC limit to outfall 001 and outfall 002
• Update TSS and COD limits to reflect current production data.
2.0 Summary
Burlington Industries, Inc., operates a textile mill in Cordova, NC (sic codes 2221 and
2231). The facility has been permitted by North Carolina since the late '70s. The facility
manufactures textured yarn and woven fabric. Manufacturing processes subject the operation to
40 CFR 410 — Textile Mills Point Source Category. More specifically, 410.32 applies, with the yarn
texturizing portion of production covered by the General Processing subcategory and the woven
fabric portion covered by the Water Jet Weaving subcategory.
Effluent limitations for BOD, COD, and TSS were originally based on effluent guidelines.
Based on observed water quality problems in the late 1980s, a field calibrated QUAL2E model
was developed for Hitchcock Creek in the early 90s. The model indicated that a tightening of
effluent limitations for the three active discharges (Burlington Industries, Laurel Hills, and
Rockingham) was necessary in order to protect the dissolved oxygen standard. In the ensuing
years, Laurel Hills ceased discharge and Rockingham planned a relocation to the Pee -Dee river.
The changes (both present and future) in Hitchcock Creek seemed to warrant a re-evaluation of
the assimilative capacity for oxygen -consuming wastes. In February of 2000, such a re-evaluation
was completed. The QUAL2E model was resurrected and run under several new scenarios.
Even with Rockingham and Laurel Hill no longer discharging to the creek, the model predicted
violations of the DO standard downstream of the Steel Mill Dam. Burlington Industries has
requested BOD limits be based on effluent guidelines. The only way for BOD limits to be based
on effluent guidelines instead of water quality is if the dam is removed. The dam is the DO
limiting factor in the system. Furthermore, the Yadkin -Pee Dee River Basinwide Water Quality
Management Plan indicates that any additional BOD loading is likely to cause dissolved oxygen
problems due to the extremely limited assimilative capacity for oxygen -consuming wastes.

NPDES Permit Fact Sheet - 06/08/04
Page 2
Burlington Industries
NCO043320
Hitchcock Creek is currently listed on the State's 303(d) list as impaired (not supporting its
designated uses). Problem parameters include pH, sediment, and fecal coliform. It is not evident
that the discharge from this facility is contributing to impairment.
Limit Development- Otctfiall 001
Burlington Industries provided 5 years (1999-2003) of daily average production data for both the
weaving and yarn texturizing operations. A four-year LTA was used to calculate technology -
based effluent limits (1999 data was omitted because it was used for the last permit renewal).
These values were 117,239 lbs/day for weaving operations and 118,1301bs/day for texturizing
operations. Note that these numbers are different than the data provided in the renewal
application, which used 2002 data. Table 1 summaries daily average production by year.
Table 1: Summa of Daily Avera a Production for Weaving and Texturizing Operations
Year
Weaving
Texturizin
2000
121,575.89
131,410.46
2001
110,736.72
116,562.45
2002
116,355.41
119,893.16
2003
120,290.58
104,656.98
LTA
117,239.65
118,130.76
Below are the effluent guidelines for weaving and texturizing operations:
Table 2: 40 CFR 410.32 Effluent Guideline Limitations
40`CFR 410.32 -
General Processing Subcategory (Texturizin)
40 CFR 410.32 -
Water jet Weaving Subcate o
BPT Limitations
BPT Limitations
1 Day Max
1 30 day
average
1 Day Max
1 30 day average
lb/1000 lbs
lb/10001bs
ED5
1.4
0.7
B0135
8.9
4.6
COD*
2.8
1.4
COD*
21.3
13.7
TSS
1.4
0.7
TSS
5.5
2.5
H
6-9 s.u.
H
6-9 s.u.
* BAT limitations
The effluent guideline limitations provided by the General Processing Subcategory can be used to
account for the texturizing component of operations and the guidelines for the Water Jet
Weaving Subcategory can be used for the weaving component of operations. Table 3
summarizes the daily loads from each portion of production and gives the total technology -based
limit recommendations.
Table 3: Technology -Based Effluent Limitations, Ibs/dav
Texturizing
O erations
Weavin
O perations
Combined
Limit
1 Day
Maximum
30 Day
Average
1 Day
Maximum
30 Day
Average
1 Day
Maximum
30 Day
Average
BOD5
165
83
1043
539
1209
622
COD
331
165
2497
1606
2828
1772
TSS
165
1 83
645
293
810
376
Existing permit limits for BOD are based on water quality concerns in Hitchcock Creek. The
receiving stream has historically shown signs of over allocation for oxygen -consuming wastes.

NPDES Permit Fact Sheet - 06/08/04 Burlington Industries
Page 3 NCO043320
The portion of the receiving stream into which Burlington discharges is listed on the 2002 303(d)
list. Problem parameters have been identified as pH, sediment, and fecal coliform. A QUAL2E
model was developed in 1992 to study the fate of oxygen -consuming materials in the creek. The
model suggested that all dischargers needed more stringent limits for BOD than those specified
in federal guidelines. Given the results of this model, it is recommended that effluent limitations
for BOD remain unchanged with limits for COD and TSS based on current production data. The
production -based limits in this permit will be slightly lower than the limits given in the previous
permit due to a slight decrease in average daily production. Table 4 compares the proposed
limits to the previous limits.
Table 4: Previous vs Proposed Effluent Limitations, lbs/day
Pollutant
Previous Permit Limits
Proposed Permit Limits
Daily Max
Monthly Average
Daily Max
Monthly Average
BOD5
836
430
836
430
COD
2962
1852
2828
1772
TSS
854
396
810
1 376
3.0 Compliance Summary
DMR Data Review
Monthly average DMR data for the period Jan 2001- Mar 2004 was reviewed for this permit
renewal. The facility appears to be well within its permitted limits for all parameters. A
summary of effluent data (at outfall 001) for the limited parameters is included in Table 5.
Table 5: Monthly Average DMR data for 2001-2004, Outfall 001
Flow
(MGD)
Fecal
W/100 mL)
D.O.
(m )
NH3-N
(lbs/da)
BOD5
(lbs/da)
TSS
(lbs/da) _
COD
(lbs/da )
Average
0.54
14.05
5.35
1.31
59.69
248.88
835.84
Maximum
0.82
175.00
6.40
8.00
128.00
372.00
1265.00
Minimum
0.34
0.34
5.20
0.36
30.00
22.50
285.00
Limit
1.2
200
5
396.6
430
396.6
1852.5
The facility was also required to monitor total nitrogen and total phosphorus levels, monthly.
Average monthly effluent values were 5.6 mg/L and 0.94 mg/L, respectively.
Outfall 002 did not have any effluent limits, however they were required to monitor flow,
temperature, TRC, and pH levels at the discharge location. The facility will receive TRC limits of
28 /cg/L at both outfalls during this renewal. Average TRC levels at outfall 001 were 57 µg/L, so
some type of dechlorination will be required, however average levels at outfall 002 were only 21
fig/L.
Since June 2003, the facility has been a member of the YPDRBMA. Prior to that time they
conducted their own instream monitoring. Data from June 2002 through June 2003 shows that
the facility does not appear to have an impact on the receiving water.
RPA Analysis
RPAs were performed for zinc, copper, fluoride and chloride. The facility exceeded allowable
concentrations for all parameters except fluoride, however as zinc, copper, and chloride are
action level parameters and Burlington is not experiencing chronic toxicity problems, they will
not receive limits. Current monitoring frequencies will remain in place for these parameters.

NPDES Permit Fact Sheet — 06/08/04 Burlington Industries
Page 4 NCO043320
There are measurable levels of fluoride in the permittee's effluent, although not at levels to
exceed water quality criteria, therefore fluoride monitoring will remain at a quarterly frequency.
WET Test Results
Burlington Industries has passed all 17/17 chronic WET tests conducted since January 2000.
Correspondence File Review/Compliance History
No significant or recurrent operational concerns were noted. Burlington Industries appear to be
well operated and in compliance with its permit conditions.
4.0 Proposed Schedule for Permit Issuance
Draft Permit to Public Notice: June 9, 2004
Permit Scheduled to Issue: August 1, 2004
5.0 State Contact Information
If you have any questions on any of the above information or on the attached permit, please
contact Toya Fields at [phone], extension 551.
Copies of the following are attached to provide further information on the permit development:
• Draft permit
• RPA analysis
NPDES Recommendation by:
Signature
Regional Office Comments: \\
NOV�U_
Date
Regional Recommendation by:
SignatureqA �\� Datc I(A A
Reviewed and accepted b3�:
-D
JUL 1 2004 J
DENR - NEATER QUALITY
POINT SOURCE BRANCH
Regional Supervisor
Signature/ ,/ \�ky I)ate
F aJ
NPDES Unit Supervisor:
Signature Date

Whole Effluent Toxicity Testing Self -Monitoring Summary May 17, 2004
FACILITY REQUIREMENT YEAR JAN IFEB MAR APR MAY JUN JUL AUG SEP OCf NOV DEC
BrennIs, Southeast. line. ehr dim: 90%
2000 -
-
- --
-
-- -
-
-- -
- -
NCOUE6827NOI Begin:INIaOUO FrequencyQ Jun Apr Jul Oct
+ NmComp:Sirne
2001 N
-
- N
-
-- N
._
--- Feu
w9 949
County: Durham Region: RED Subbmi¢ CPFOS
2002 Pass
-
- Fell
92.5
31.9 Fall
X
31.9,92.6 Pass
- -
PF: 0.01" Sprain
JUN care
Pass
- Pam
-
- Pat.
--
-- Pass
- ...
7QIO: 0.0 IWC(%)IOU 0Nm
NO4 Is
Pao
-
Brev.rdtYIVTP chr Om: 2A%
g NOO Pass
-
- Pass
-
- Pass
-
- Pass
-- -
NC0060534/001 Begin UIPOOi FrequencyQ Im Am Jul Oct
+ NmComp:Single
NU1 Pas
-
- Fail
m9
Ns Pass
--
-- Pass
-- -
County: Transylvania Region ARO Subbain: FRBOI
gang Pas.
-
-- Pass
-
- Pa..
--
-- Pass
- -
PF. 2.5 Smriel
no Pass
-
-- Pass
-
- Pass
-
-- Pass
- -
7QIO:161.0 ItVC(%)2.4 Omen
NOW Pass
-
--
BrysonCityIVWTP chr limn 0.25%
WOO Pas
-
- NR
Pass
- Pm,
--
- Paso
- -
NCO026557NOI Begim5/1,2003 FrequencyQ Jan Apr Jul Oct
+ Noncomp:Single
not Pm.
-
- Pass
-
- Pau
-
-- NwPam
- -
County: Swain Region: ARO Subbnsia: LTNO2
Noy MUPas
-
- Pass
-
- Pans
-
- Pass
- -
PF: 0.60 SM 1
NOO Pas
-
- .as
-
- Pam
-_
_ Pam
7QIO: 365.0 IWC(%)0.253 Under:
20M Pa.
-
-
BurmycLumberton, Inc. chr Him: 3.1%; ifpf4MGD chr dim 4.9%
¥2OW -
Pass
- -
pass
- -
Pass
- --
Pass -
NCO1105321/Onl Begin 3/II2000 FrequenyQ Feb May Aug Nov
+ NocComp:Single
not -
Paas
- -
Pass
- --
Pass
- -
Pee. -
Coumy: Robeson Region: FRO Subinsm: LUM51
2002 -
Pau
- -
Pas
- -
Pass
- -
Pass -
PF:2.5 Somali
Will -
Pau
- -
Pau
- -
Pau
N
7QIO: 119.28 IWC(%)2.3 Omer
no, -
-
BulesCreek %V\VTP 24hr an p/f lim: 91
Not Pam
-
- Paas
-
-- Pass
-
-- Pau
- -
NC0030U91AIU1 Benn5/1/1996 FrequenyQ + Jan Apr JNIOct
NmComp,Single
Nor Pass
-
- Pass
-
-- Pass
-
-- Pass
- -
County: Hamer Region: FRO Subbmin: CPFln
2002 Pass
-
-- Pm.
-
-- Pas
--
-- Pas.
- -
PF: 0.50 Somali
N0.9 Pas
-
- Pas.
-
- Pas.
--
-- Pass
-
7QIO: NO I%VC(%)O.13 Order.
Most Pas.
_
_
Bunicall County MSD chr Iran 12%
JUN -
Fail
339 Ma
Nis
- -
339
- -
399 -
NCOO24911/001 Brida:2/12001 FrequencyQ Feb May Aug Nov
+ NonCompsingle
2001 -
11
- -
M.9
-- -
33B
- -
>24 -
Counsy:Buncombe Region: ARO Subbmin: EM02
2002 -
73
17 294
294
-- -
17
- -
1697 -
PF:40.0 Sonia)
No -
r04
17 7.3
>24
- -
>36
- -
>36 -
7QIO:466.0 IWC(%) 12.0 oiler.
20M -
29.4
...
Bunn WWTP Our hen: l I%
2000 -
-
Pua
-
-
Pau
Fell
Pau
>100
>100
N000,42261i Begin11/172000 Fort umry.Q Mar Jun Sep Dec
+ NonComp:Single
nor -
-
Pau
-
-
Pass
-
-
Latelial
>N
>20
Pam
County: Franklin Region: RRO Subbaim TAR01
WW2 -
-
Pam
-
-
Pala
-
-
Pau
-
-
Pau
PF: 0.15 Sproul
21
Pau
Paaa
-
-
Pua
-
-
Pas,
7QIU; I.g IWC(%) II Order
Na -
-
Pass
Burl WWTP she limn 90%
20M -IN
-
-
-IN
-
...
.100
--
-
>100
-
-
NCW21113/001 Begin ll/1/2103 FTequmcy.Q Jan Apr Jul Oct
+ NonComp. Single
2001 -IN
--
-
>1N
-
-
-I00
--
-
949
-
-
COunty:Pender Region: WIRO Subbmian CPF23
200256.1
>tm
-
slog
-
-
7ge
stop
-100
>100
-
-
PF: 0.75 Sorest
2X3 >IN
-
_-
>IN
-
.-
>IW
._
_.
>IDO
-
-
]QI0:0.0 IWC(%)IW Orden:
Mail slop
--
-
BarlingmaEast`Vi chr limn 36%
¥Not
Pau
-
-
Pau
-
-
Pa.
-
-
Pass
-
N000Dtl6X/001 Begirt N1/2002 FrequencyQ Feb May Aug Nov
+ NonComp151NGLE
2001 -
Pass
--
--
Pass
-
--
Pass
-
-
Pas.
-
County:Almiance Region: WSRO Subbrin: CPF02
2002 -
Pa.s
--
--
Pass
--
-
Pass
-
-
Pa..
-
PF: 12.0 lentil
JUN -
Pau
--
--
Pass
--
-
Pau
-
--
Pass
-
7QIO:13.6 IWC(%)36 Our—
2004 -
Pau
--
Ourlingsanlnd.Rlehmand chr lint:]%
2000 -
Pau
-
-
Pass
-
-
Pau
-
-
Pass
-
NC004J32000I Begin NI20U11 Prequency.Q Feb May Aug Nov
+ NmCmi Single
2001 -
Pass
-
--
Paas
-
-
Pau
-
-
Peas
-
County: Richmond Region: FRO Subbuia: YADI6
Olm2 -
Pass
-
--
Pass
--
-
NmFa s
-
-
Pa..
-
PF: 1.2 S"it
2003 _
Pau
Pas.
-
-
Pass
--
-
Pam
-
7QIO:25.0 IWC(°A)7.0 Order
2004 -
Pass
-
Bur11nglon-South IVWTP chr hen: 86%
y2000 Fall
snort
-list
Pa.s
-
-
Flo
NO
>1W
Pasa
-
-
NCOU23876/WI Begialiclam2 Fequsco,Q Jan Apr Jul Oct
+ Noncon asingle
2001 Pens
-
-
Pas
-
-
Pam
-
-
Pea
-
-
Coumy:Alamance Region: WSRO Subbmin:CPF02
2002 Pau
-
-
Pam
-
-
Pam
"-
-
Pass
-
-
PF: 12.0 Sleci>I
2003 Pau
-
-
Pass
-
-
Pam
--
-
Fail
>tOt
-IN
7Q10: 3.0 IWC(%)g6 amr:
2m4 Pam
_
_
Burmvllle WWTP chrlinn 6%
y2000--
-
Pat.
-
-
Pass
-
-
Pas.
-
--
Pe..
NCW202901001 Begin:2/IQ003 Fro miQ Mar Jun Sep ON
+ NNCNgFShgle
Not --
-
Pau
-
-
Paas
-
-
P...
-
-
Pea.
County. Yancey Region: ARO Subbasin: FRB07
2002 --
-
Pam
-
-
Pau
-
--
Is...
--
--
Paas
PF: O.g Spread
Not -
-
Pam
-
-
NR/Pam
-
--
Pau
---
Pa.s
7QIU: 19.0 IWC(%)6.0 Oa"i
2004 -
-
Pam
LEGEND:
PERM =Permit Res mamenl LET- Adermismllve Leon- Target Frequency = Monitoring frequsucy Q-Quarterly; M-MonWy;BM-Bimonthly,SA- Semiannually; A- Annually; OW0.0Ny hen diuhatging; D- Discontinued manimring requirement
Begin-Firstamearequircd ]Q10=Raeiving stream law Bow criterion lets)=quartedymnameneglncrensesmmonrhlyupon failurear NR Monshsthaltestingmmtoccur-enlan,Apglul,0a NpnComp=Co Commit Compliance Uncommon
PF-Permandlow(MGD) IWC%=hwmmnwutemummion P/F=Pass/F ,in AC - Acute CUR =Clarence
Dam Notation: r-Pubertal Minnow; - - Cedadaphau sp.; my- Mysid shrimp; ChV -Chmnic value; P- Mortality alarmed peremlage as Inghca commeradon; at- Performed by DWQ Albanian To. Out,; Or- Bed suss
Reporting Notation :--= Dam not required; NR - Nor reported Facility Activity Stmu: 1-Inactive. N - Newly kcami coaauce;H- Active but net discharging,) -Mom& in available far month in question;c= ORC signal needed
5

REASONABLE POTENTIAL ANALYSIS
Burlington Industries
NCO043320
Time Period March 2004-March 2001
Ow (MGD) 1.2
WWTP Class III
7010S (cfs) 25
1WC (%) ®7010S 6.9248
701OW (cfs) 68
® 701OW 2.6625
3002 (cfs) 0
® 3002 WA
Avg. Stream Flow, OA (cfs) 174
0 QA 1.0577
Rec'ving Stream Hitchcock Creek
Stream Class C
Outfall 001
Ow =1.2 MGD
STANDARDS &
PARAMETER
TYPE
CRITERIA (2)
POL
Units
REASONABLE POTENTIAL RESULTS
RECOMMENDED ACTION
(1)
NcW031 KFAV/
rt IOft flax ProdCW AOombkCW
chronk Acuk
Acute: 67
Retain monthly monitoring
Zinc
NC
50 AL 67
ug/L
40 27
745.5
Chronic: -- 722 —
--------------------•-------•--
Acute: 7
Retain monthly monitoring
Copper
NC
7.0 AL 7.3
ugiL
40 8
71.3
Chronic: 1_01 —
----------------------------•--
Acute: WA
Retain quarterly monitoring
Fluoride
NC
1800
ag/L
13 13
717.4
- _ _ _ _ _ _
--------•---.—.—.---•----------
Chronic: 25.994
Acute: WA
Retain quarterly monitoring
Chloride
NC
230 AL
ug/L
13 13
6452.9
Chronic: -----------------------------------
Acute: 67
Analysis excludes data prior to Oct 2001 (to exclude
ZInc2
NC
50 AL 67
ug/L
31 19
88.2
uncharacteristic spikes- possible unit conversion error)
•----
Chronic: 722
--------------------------
Acute: WA
0 0
WA
_ _ _ _
Chronic::rror ®-Type
----•--------------------------
Acute: WA
0 0
WA
___
Chonic:r:rror ®-Type --------•-------•--------------
Acute: WA
0 0
WA
Chronic::rror 0-Type
I
--•—•—•---•—•—•—•---•----------
Acute: WA
0 0
WA
_hr_ ___
Conic::rror Type
-------------------------------
Acute: WA
0 0
WA
_
Chronic: :nor -Type ------•-----•---.—.------------
Acute: WA
1
-
• Chronic::rror 0 Type
------------•—•-----•----------
Acute: NIA
0 0
WA
---- -
Chronic::r—ror— Type
--------------------•—•--------
Acute: WA
0 0
WA
----
_
Chronic: error_ -Type
---------.—.—.—.—.-------
Acute: WA
0 0
WA
_____
Chronic; -rror ®Type
---------------------•—•—•—•--
Acute: WA
0 0
WA
_ _ _ --------------------------------
Chronic: Error ® -Type
Legend: " Freshwater Discharge
C = Carcinogenic
NC = Non -carcinogenic
A = Aesthetic
43320_rpa.xls, rpa
6/3/2004

REASONABLE POTENTIAL ANALYSIS
1
Zinc
Date
Data
BDL=1/2DL
Results
1
Mar-2004
17
17.0
Std Dev.
37.2737
2
Feb-2004
<
10
5.0
Mean
22.1750
3
Jan-2004
13
13.0
C.V.
1.6809
4
Dec-2003
18
18.0
n
40
5
Nov-2003
20
20.0
6
Oct-2003
22
22.0
Mutt Factor =
3.5500
7
Sep-2003
12
12.0
Max. Value
210.0 ug/L
8
Aug-2003
<
10
5.0
Max. Pred Cw
745.5 ug/L
9
Jul-2003
13
13.0
10
Jun-2003
15
15.0
11
May-2003
25
25.0
12
Apr-2003
19
19.0
13
Mar-2003
<
10
5.0
14
Feb-2003
<.
10
5.0
15
Jan-2003
<
10
5.0
16
Dec-2002
24
24.0
17
Nov-2002
<
10
5.0
18
Oct-2002
<
10
5.0
19
<
10
5.0
20
Sep-2002
<
10
5.0
21
Aug-2002
<
10
5.0
22
Jul-2002
11
11.0
23
Jun-2002
12
12.0
24
May-2002
<
10
5.0
25
Apr-2002
15
15.0
26
Mar-2002
42
42.0
27
Feb-2002
14
14.0
28
Jan-2002
16
16.0
29
Dec-2001
14
14.0
30
Nov-2001
<
10
5.0
31
Oct-2001
12
12.0
32
Sep-2001
104
104.0
33
Aug-2001
104
104.0
34
Jul-2001
14
14.0
35
Jun-2001
13
13.0
36
May-2001
15
15.0
37
Apr-2001
<
10
5.0
38
Mar-2001
13
13.0
39
Feb-2001
15
15.0
40
Jan-2001
210.0
210.0
43320 rpa.xls. data
-1 - 6/4/2004

REASONABLE POTENTIAL ANALYSIS
Date Data
BDL=1/2DL
Results
1 m 10
5.0
Std Dev.
5.8995
2 10
&0
Mean
Z3750
3 10
5.0
C.V.
0.7999
4 10
5A
n
40
5 10
5.0
6 10
5.0
Mult Factor =
2.1600
7 10
5.0
Max. Value
33.0
8 10
5.0
Max. Fred Cw
71.3
9 33
33.0
10 10
5.0
11 10
5.0
12 10
5.0
13 10
5.0
14 10
5.0
15 11
11.0
16 24
24.0
17 13
13.0
18 10
5.0
19 19
19.0
20 10
5.0
21 10
5.0
22 10
5.0
23 14
14.0
24 10
5.0
25 10
5.0
26 10
5.0
27 10
5.0
28 10
5.0
29 10
5.0
30 10
5.0
31 10
10.0
32 10
5.0
33 10
5.0
34 10
5.0
35 10
5.0
36 10
5.0
37 10
5.0
38 10
5.0
39 10
5.0
40 11
11.0
43320_rpa.xls. data
- 1 - 6/4/2004

REASONABLE POTENTIAL ANALYSIS
3
Date C
tl
ata BDL=1/2DL Results
4 Std Dev. 63.8610
110 110.0 Mean 103.8308
C.V. 0.6150
n 13
50 50.0 Mult Factor = 2.7700
Max. Value 259.0
�# 71.5 71.5 Max. Pred Cw 717.4
132 132.00
189 189.00
259 259.00
82.3 82.30
80 80.00
10 10.00
121 121.00
104 104.00
55 55.00
86 86.00
43320_rpa.xls, data
6/4/2004

REASONABLE POTENTIAL ANALYSIS
4
Date Data BDL-112DL Result,
Std Dev.
., 2049 2049.0 Mean
C.V.
n
1500 1500.0 Mult Factor=
Max. Value
1120 1120.0 Max. Fred Cw
1900 1900.0
1640 1640.0
2290 2290.0
2980 2980.0
2270 2270.0
2060 2060.0
3730 3730.0
2090 2090.0
2400 2400.0
3030 3030.0
694.5919
2235.3077
0.3107
13
1.7300
3730.0 ug
6452.9 ua
-1-
43320_rpa.xls, data
6/4/2004

-Tr
DIVISION OF WATER
October 8, 2003
MEMORANDUM
Eod
OCT 11 2 003 lul
DENRMATER QUALITY
POINT SOURCE BRANCH
TO: Dave Goodrich, Unit Supervisor
NPDES Permitting and Engineering Unit
FROM: Dale Lopez
Environmental Specialist
THRU: ul E. Rawls, Water Quality Regional Supervisor
Fayetteville Regional Office
SUBJECT: Staff Report of NPDES Permit No. NCO043320
Burlington Industries, Inc.
Richmond Plant, Cordova, North Carolina
Richmond County
Please find attached the staff report and recommendations concerning the renewal of
subject NPDES permit.
If you have any questions or require further information, please advise.
Fowl?
Attachment

� r
SOC PRIORITY PROJECT: YES NO
-L -/
If Yes, SOC No.
To: Permits and Engineering Unit
Water Quality Section
Attention: Charles Weavers
Date: October 7.2003
NPDES STAFF REPORT AND RECOMMENDATION
COUNTY: Richmond
Permit No. NC0043320
PART I - GENERAL INFORMATION
1. Facility and Address: Burlington Industries
PO Box 250
Cordova, North Carolina 28330
2. Date of Investigation: August 21, 2003
3. Report Prepared by: Dale Lopez, Environmental Specialist
Fayetteville Regional Office
4. Persons Contacted and Telephone Number: Paul Smart, ORC
910-417-2207
5. Directions to Site: The site is located at the junction of SR1103 and SR1109 in Cordova.
6. Discharge Point(s), List for all discharge points:
Latitude: 34° 55' 04" Longitude: 79° 49' 51"
Attach a U.S.G.S. map extract and indicate treatment facility site and discharge point on map.
U.S.G.S. Quad No. H 19 NE U.S.G.S. Quad Name: Rockingham, NC
7. Size (land available for expansion and upgrading): Approximately 60 acres.
8. Topography: (relationship to flood plain included): Flat
9. Location of nearest dwelling: Approximately 600 feet.
10. Receiving stream or affected surface waters: Hitchcock Creek
a. Classification: "C"
b. River Basin and Subbasin No.: Yadkin 03-07-16
C. Describe receiving stream features and pertinent downstream uses:
Fish and wildlife propagation, agriculture, and other
uses requiring waters of lower quality.

PART H - DESCRIPTION OF WASTES AND TREATMENT WORKS
1. a. Volume of wastewater to be permitted: 1.2 MGD (Ultimate Design Capacity)
Type of wastewater: 3% Domestic
97% Industrial
Types and quantities of industrial wastewater: Current Average Flow (GPM
Process 0.39 MGD
Sanitary 0.01 MGD
Boiler Blowdown 0.01 MGD
Cooling Down 0.08 MGD
b. What is the current permitted capacity of the Wastewater Treatment facility? 1.2 MGD
C. Actual treatment capacity of the current facility (current design capacity). 1.5 MGD
d. Date(s) and construction activities allowed by previous Authorizations to Construct issued in
the previous two (2) years. N/A
e. Please provide a description of existing or substantially constructed wastewater treatment
facilities:
The existing treatment system consists of a 1.5 MGD capacity facility
consisting of two (2) aeration basins in parallel (a total of 48 hours detention),
two (2) clarifiers in parallel, disinfection facilities, an aerobic sludge digester,
and sludge drying beds.
f. Please provide a description of proposed wastewater treatment facilities: N/A
g. Description of industrial process (for industries only) and applicable CFR Part and Subpart:
Burlington Industries is a textile plant which utilizes yarn texturing
and slashing, and water jet loom weaving of polyester cloth to
generate the wastewater stream.
h. Possible toxic impacts to surface waters: N/A
h. Pretreatment Program (POTWs only): N/A
In development Approved
Should be required Not needed X
2. Residuals handling and utilizing/disposal scheme:
a. If residuals are being land applied, please specify DWQ Permit No. N/A
Residual Contractor: N/A
Telephone:
b. Residuals stabilization: PSRP PFRP Other N/A
C. Landfill: N/A

o � .
PART H - DESCRIPTION OF WASTES AND TREATMENT WORKS (continued)
d. Other disposal/utilization scheme (specify): N/A
3. Treatment plant classification (attach completed rating sheet): Class III
4. SIC Code(s): 2221 (Broadwoven Fabric Mills, Manmade)
2231 (Broadwoven Fabric Mills, Wool)
PrimaryO1 Secondary 04
Main Treatment Unit Code: 0 5 0 0 1
PART III - OTHER PERTINENT INFORMATION
1. Is this facility being constructed with Construction Grant Funds or are any public monies involved
(municipals only)? N/A
2. Special monitoring or limitations (including toxicity) requests: N/A
3. Important SOC, JOC, or Compliance Schedule Dates (please attach): N/A Date
Submission of Plans and Specifications.................................................... N/A
Begin Construction.................................................................................... N/A
CompleteConstruction.............................................................................. N/A
4. Alternative Analysis Evaluation: Has the facility evaluated all of the nondischarge options available?
Please provide regional perspective for each option evaluated.
Spray Irrigation: N/A
Connection to Regional Sewer System: N/A
Subsurface: N/A
Other Disposal Option: N/A
5. Other Special Items: N/A

f
PART IV - EVALUATION AND RECOADMNDATIONS
It is the recommendation of the Fayetteville Regional Office that the subject permit application be processed
and the appropriate permit be issued in keeping with basinwide management requirements. This (active)
permit will not expire until February 29, 2004.
Sign a of Report Preparer
Water Quality Regional Supervisor
io 13103
Date

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
September 11, 2003
Doug Carter
Burlington Industries, Inc
P. O. Box 250
Cordova, NC 28330
SUBJECT: August 21, 2003 Compliance Evaluation Inspection
Burlington Industries, Inc
Burlington Industries/Richmond
Permit No: NCO043320
Richmond County
Dear Mr. Carter:
Enclosed please find a copy of the Compliance Evaluation Inspection form from the inspection conducted
on August 21, 2003. The Compliance Evaluation Inspection was conducted by Belinda S Henson of the
Fayetteville Regional Office. The facility was found to be in Compliance with permit NC0043320. The
cooperation of Mr. Paul Smart, ORC and Ms. Dorothy Quick, Backup Operator were greatly appreciated.
As a reminder preservation of the Waters of the State can only be acquired through consistent NPDES
permit compliance.
Please refer to the enclosed inspection report for additional observations and comments. If you or your staff
have any questions, please call me at 910-486-1541.
cc: Paul Robert Smart, ORC
Central Files
Fayetteville Files
Sincerely,
4. 94L.-A�rk-)
Belinda S Henson
Environmental Chemist
wi
NCDENR Division of Water Quality
Customer Service 1 877 623-7748
225 Green Street -Suite 714 Fayetteville, NC 28301-50431 [phone] Telephone
[phone] Fax

NPDES COMPLIANCE INSPECTION REPORT
North Carolina Division of Water Quality
Fayetteville Regional Office
Section A. National Data System Coding
Transaction Code: N NPDES NO. NCO043320 Date: 030821
Inspector: S Facility Type: 2
Facility Evaluation Rating: 4 BI: N QA: N
Section B: Facilily Data
Name and Location of Facility Inspected:
Burlington Industries WWTP
Entry Time: 10:20am
Exit Time/Date: 12:40pm/030821
Name(s), Title(s) of On -Site Representative(s):
Paul Smart (Certified Grade III) - "ORC"
Dorothy Quick (Certified Grade II) - "Backup Operator"
Phone Number(s): [phone]/[phone]
Name, Title and Address of Responsible Official:
Mr. Doug Carter, Plant Manager
PO Box 250
Cordova, NC 28330
Section C: Areas Evaluated During Inspection
Inspection Type: C
Reserved:
Reserved:
Permit Effective Date: 000601
Permit Expiration Date: 040229
Contacted: no

Section D: Summary of Findings/Comments:
1. The facility produces unfinished cloth for apparel wear. This facility does not dye cloth.
2. The manual bar screen appeared to be operational with all screenings disposed of through the county
landfill.
3. The aeration basins are both operational. One aeration basin is utilized for treatment of wastewater
while the other is basically a standby. Basin # 1 contains two (2) aerators and one (1) mixer. The
aerators are set on timers that allow the aerators to be switched every 10 minutes and operate 4
minutes.
4. The two (2) clarifiers were operational. In clarifier #1 there was 1.5 feet of sludge and in clarifier
#2 there was 3 feet of sludge. The skimmer arms appear to have paint worn from the surface. These
areas should be painted in the near future to eliminate major repairs in the future.
5. Chlorine is added to the influent to assist with disinfection.
6. The effluent appeared to have some fine floc not excessive. The effluent (001) and cooling water
(002) are discharged separately but they flow into a central pipe which is located across the road
from the wastewater facility. It then flows to Hitchcock Creek. The cooling water (002) was
observed during the inspection and it appeared to be free of solids and no color noted.
7. The effluent composite sampler temperature was 0 degrees Celsius. The acceptable temperature
range of samples during storage and for stored sample extracts, is 1.0 to 4.4 degrees Celsius. Ref:
Federal Register, July 1, 1995; 40 CFR 136; Table 11. The effluent composite sampler is flow
proportional by constant time/variable volume collection.
8. The effluent flow meter was calibrated August 20, 2003 by facility staff Mr. Bill Thompson.
9. The aerobic digester is operational but sludge wasting has not been necessary as per Ms. Quick.
Sludge from the clarifiers are recirculated back into the aeration basin. The scum scraped from the
top of the clarifiers are pumped to the digester.
10. Sludge drying beds are on site to assist with disposal if necessary.
11. The grounds were neat and clean.
12. Maintenance is completed by staff through computer generated work orders. All maintenance and
facility records were well documented.
13. The facility has field parameter certification #5061 for the following parameters: pH, DO,
Conductivity and Temperature. Microbac analyzes the remaining NPDES permit parameters with
the exception of Toxicity, which is completed by Similabs. A cursory lab inspection revealed all
pH standard expirations were adequate. The Total Chlorine Residual standards expired June 3,
2003. Ms. Quick communicated during the inspection that those standards would be purchased
immediately.
-continued-

14. A compliance report for the period May 2002 through May 2003 revealed that there were not any
violations for that period.
15. Laboratory records were reviewed for the period December 2002 and January 2003 and compared
to Discharge Monitoring Reports (DMRs). All records reviewed appeared to be neat and organized.
THE NPDES PERMIT EXPIRES FEBRUARY 299 2004. The facility is presently working on the
renewal package. AS A REMINDER THE RENEWAL SHOULD BE COMPLETED AND SENT TO
THE NPDES PERMITTING UNIT IN RALEIGH WITHIN 180 DAYS OF EXPIRATION.
Name and Signature of Inspector Agency/Office/Telephone Date.
Belinda S. Henson DENR/Fayetteville/[phone] S - f 1- 63
Name and Signature of Reviewer Agency/Office/Telephone Date
Paul E. Rawls DENR/Fayetteville/[phone]
Regulatory Office Use Only
Action Taken Compliance Status Date
Noncompliance
_Compliance

Sectlon D; Summary of Findings/Comments
Brief Facility Description:
GD WWTP ggn§isting of thefoll win • tw aeration b si i rall 1 twg-clarifim in
11arallgl. dis'nfe ti n facilities, aerobic sludec di es ion and sludge drying
FACILITY SITE REVIEW
es No N/A 1. Treatment units properly operated and maintained.
1��ej No NIA 2. Standby power or other equivalent provision provided.
es No N/A 3. Adequate alarm system for power or equipment failure available.
4. Sludge disposal procedures appropriate:
Yes No N/A a. Disposal of sludge according to regulations
Yes No N/A b. State approval for sludge disposal received.
es - No N/A 5. Sufficient sludge disposed of to maintain treatment process equilibrium.
CYY3'e� No N/A 6. The ORC and Backup Operator are officially designated with
NCDENR/DWQ Training and Certification Unit.
Yes? No N/A 7. Adequate spare parts and supplies inventory maintained.
es No N/A 8. Plant has general safety structures such as rails around or covers over
tanks, pits, or wells.
�e- No N/A 9. Plant is generally clean, free from open trash areas.
10. Screening:
(j�gs) No N/A. a. Manual
Yes No ( ' b. Mechanical
Yes (L�O-- N/A c. Buildup of debris
Ye 'Q' N/A d. Screenings properly disposed of.
11. Grit Removal:
Yes No (Sw a. Excessive organic content in the grit chamber
Yes No N/A b. Excessive odors
Yes No N/A c. Grit properly disposed of.

Page 2
12.
Primary clarifier:
Yes
No
OAD
a.
Excessive gas bubbles
Yes
No
N A
b.
Black and odorous wastewater
Yes
No
N/A
c.
Poor suspended solids removed
Yes
No
N/A
d.
Excessive buildup of solids in center well of circular clarifier
Yes
No
N/A
e.
Weirs level
Yes
No
N/A
f
Weir blockage
Yes
No
N/A
g.
Evidence of short circuiting
Yes
No
N/A
h.
Lack of adequate scum removal
Yes
No
N/A
i.
Excessive floating sludge
Yes
No
N/A
j.
Broken sludge scraper.
13. Trickling Filter:
Yes
No
a:
Trickling filter ponding(indicating clogged media)
Yes
No
N/A
b.
Leak at center column of trickling filter's distribution arms
Yes
No
N/A
c.
Uneven distribution of flow on trickling filter surface
Yes
No
N/A
d.
Uneven or discolored growth
Yes
No
N/A
e.
Excessive sloughing of growth '
Yes
No
N/A
f
Odor
Yes
No
N/A
g.
Clogging of trickling filter's distribution arm orifices
Yes
No
N/A
h.
Filter flies, worms, or snails.
14. Activated Sludge Basins/Oxidation Ditches:
On No
N/A
a.
Dead spots
Yes
(0) N/A
b.
Failure of surface aerators
Yes
No) N/A
c.
Air rising in clumps
Yes
(RD N/A
d.
Dark foam or bad color
Yes
& N/A
e.
Thick billows of white, sudsy foam
Yes
No
/'A:�
f.
Air rising unevenly
Yes
No
tiLYL
g.
Excessive air leaks in compressed. air piping.
15.
Stabilization Ponds/Lagoons:
Yes
No
C/
a. Excessive weeds including duckweed in stabilization ponds
Yes
No
N/A
b. Dead fish or aquatic organisms
Yes
No
N/A
c. Buildup of solids around; influent pipe
Yes
No
N/A
d. Excessive scum on surface.

Page 3
16.
Secondary Clarifier:
Yes (g) N/A
a.
Excessive gas bubbles on surface
Yes No N/A
b.
Level overflow weirs
Yes Q�!) NIA
c.
Weir blockage
Yes ® N/A
d.
Evidence of short circuiting
YesN/A
e.
Excessive buildup of solids in center well of circular clarifier
Yes No N/A
f.
Pin floc in overflow 4&*w Ytet
� No N/A
g.
Effective scum rake
Yes (Kb> N/A
h.
Floating sludge on surface
Yes 4W N/A
i.
Excessive high sludge blanket
Yes � j N/A
j.
Clogged sludge withdrawal ports on secondary clarifier.
17.
Filtration:
Yes
No A
a.
Filter surface clogging
Yes
No
N/A
b.
Short filter run
Yes
No
N/A
c.
Gravel displacement of filter media
Yes
No
N/A
d.
Loss of filter media during backwashing
Yes
No
N/A
e.
Recycled filter backwash water in excess of 5 percent
Yes
No
N/A
f.
Formation of mudballs in filter media.
18.
Chlorination Unit:
Yes
No
9D
a.
Sludge buildup in contact chamber
Yes
No
NIA
b.
Gas bubbles
Yes
No
N/A
c.
Floating scum and/or solids
Yes
No
N/A
d.
Adequate ventilation of chlorine feeding room and storage area
Yes
No
N/A
e.
NIOSH-approved 30 minute air pack
Yes
No
N/A
f.
All standing chlorine cylinders chained in place
Yes
No
N/A
g.
All personnel trained in the use of chlorine
Yes
No
N/A
h.
Proper chlorine feed, storage, and reserve supply.
Yes No 19. Ultraviolet radiation disinfection present and in use.
20. Dechlorination:
Yes No a. Proper storage of sulfur dioxide cylinders
Yes No N/A b. Adequate ventilation of sulfur dioxide feeding room
Yes No NIA c. Automatic sulfur dioxide feed or feedback control operating
properly.
21. Aerobic Digester:
Yes (g N/A a. Excessive foaming in tank
Yes M NIA b. Noxious odor
Yes qL ) N/A c. Mechanical aeration failure
Yes No <IKD d. Clogging of diffusers.

Page 4
22. Anaerobic Digester:
Yes No (RP a. Floating cover tilting
Yes No N/A b. Gas burner operative
23. Sludge Drying and/or disposal:
Yes
No
N/A
a.
Poor sludge distribution on drying beds
Yes
No
N/A
b.
Vegetation in drying beds
Yes
No
N/A
c.
Dry sludge remaining in drying beds
Yes
No
N/A
d.
Dry sludge stored on site
Yes
No
N/A
e.
Filtrate from sludge drying beds returned to front of plant
Yes
No
N/A
f.
Sludge disposal through county landfill.
Yes
No
N/A
g.
Sludge land applied.
24. Filter Press:
Yes No M:7 a. High level of solids in filtrate from filter presses or vacuum filters
Yes No N/A b. Thin filter cake caused by poor dewatering
Yes No N/A c. Sludge buildup on belts and/or rollers of filter press
Yes No N/A d. Excessive moisture in belt filter press sludge cake.
25. Polishing Ponds or Tanks:
Yes No OW"
a.
Objectionable odor, excessive foam, floating solids, or oil sheens on
water surface
Yes No N/A
b.
Solids or scum. accumulations in tank or at side of pond
Yes No N/A
c.
Evidence of bypassed polishing ponds or tanks because of low
capacity.
26. Plant Effluent:
Yes QW1 N/A
a.
Excessive suspended solids, turbidity, foam, grease, scum, color, and
other macroscopic particulate matter present
Yes No) N/A
b.
Potential toxicity (dead fish, dead plant at discharge)
Yes No N/A
c.
Outfall discharge line easily accessible.
27. Flow Measurement:
(Yes No N/A
a.
Proper placement of flow measurement device
eS No N/A
b.
Flow meter calibrated
Yes N/A
c.
Buildup of solids in flume or weir
Yes N/A
d.
Broken or cracked flume or weir
Yes 0.a� N/A
e.
Clogged or broken stilling wells
Yes N/A
f.
Weir plate edge corroded or damaged
Yes No N/A
g.
Flow measurement error less than 10%.

Page 5
28. Sampling:
60) No N/A a. Sampling and analysis completed on parameters specified by permit
No N/A b. Composite sample temperatures maintained at 4 degrees Celsius or
less (but above freezing) during sampling
es No N/A c. Contract laboratory used for sample analysis
Yes? No N/A d. Effluent composite samples obtained are flow proportional.
RECORDKEEPING AND REPORTING
Ci'ei-
-No N/A 1. Records and reports maintained as required by permit.
es No N/A 2. All required information available, complete, and current.
2Ye7No N/A 3. Records maintained for 3 years and all sludge records maintained for 5
years.
Ye �>No N/A 4. Analytical results consistent with data reported on DMRs.
5. Sampling and analyses data adequate and include:
es No
N/A
a. Dates, times, and location of sampling
No
N/A
b. Name of individual performing sampling
(Vest No
N/A
c. Results of analyses and calibration
es No
N/A
d. Dates of analyses
es No
N/A
e. Name of person performing analyses.
6. Monitoring records adequate and include:
(e No N/A a. Monitoring charts kept for 3 years
Le-s No N/A b. Flowmeter calibration records kept for 3 years.
es > No N/A 7. The pH meter is calibrated daily with two buffers and checked with a
third buffer and properly documented.
e:s) No N/A 8. Expiration dates of pH buffers adequate.
No N/A 9. All thermometers used in NPDES permit reporting is calibrated
annually with an MIST certified thermometer or a traceable
thermometer annually and documented.
CY�DsNo N/A 14. The following NPDES permit required parameters are analyzed on site:
pH, Temperature, Dissolved Oxygen and Chlorine Residual.

Page 6
es )No N/A 11. The NPDES permit required parameter Total Chlorine Residual is
analyzed by approved method.
Yes No (/A- 12. BOD incubator temperature maintained at 20 +/- 1 Degrees Celsius
and the temperature maintained in a log for every day of operation.
Yes No � 13. Fecal coliform incubator maintained at 44.5 +/- 0.2 Degree Celsius and
the temperature maintained in a log for every day of operation.
14. Plant records adequate and include
Ms> No N/A a. O & M Manual 49 46P
es No NIA b. "As -built" engineering drawings
C s No N/A c. Schedules and dates of equipment maintenance repairs
Yes No N/A d. Equipment data cards.
Yes No N/A 15. Permittee is meeting compliance schedule.
Yes )No N/A 16. DMRs complete and include all NPDES permit required parameters.
Yes No 17. The facility has a permitted flow greater than 5 MGD and is required
to operate seven days per week 24 hours a day.
es No N/A 18. ORC visitation logs available and current.
Yes ;No N/A 19. ORC certified at a level equal to or greater than the classification of
the wastewater facility.
es)No N/A 20. Backup Operator certified at one level less than the classification of
the wastewater facility or greater.
es �No N/A 21. Current copy of the complete NPDES permit on site.
Ye3--iNo N/A 22. Facility description verified as contained in NPDES permit..
-------------
Yes No N/A 23. Facility analyzes process control parameters for example: IVESS,
MCRT, Settleable Solids and others that are applicable.
Yes No (VA—) 24. Industrial Waste Surveys (1WS) sent to all possible Significant
Industrial Users (SIUs) within the last five years (especially new
industries).
Revised 7/16/01
by Belinda Henson

` Regional Field Inspectors Check t_Ist Tor r�eto
,� o w Date: �' - " D 3
Vame of site to be Inspected:
•applicable):I Inspector:_Le-It"oola-S. l�eY�.�'o ti
-field certification # (if
NPDES#:,N( Ud 332
0 Region:
' cle the ar [meter orparameters- performed at this slte.
i. Cyr
esldual Chlorine Settleable Solid : p onductivity, e�mpe�ratu
11. Instrumentation:
Does the facility have the equipment necessary to analyze field parameters as circled above?
A. Do y � �� go 6
1 . A pH meter
es No {�cc�'�n.c� P
A Residual Chlorine meter
No ��r-c'�� .
2. Ce& -Pavyru"o d� •ram
3. DO meter
e� No
4. A Cone for settleable solids
Yes
No .
5. A thermometer or meter that measures temperature.
Yes
No
No
6. Conductivity meter
es f
1i1. Calibration/Analysis:.
1. Is the pH meter calibrated with a 2 buffers and
a
No
checked with a third buffer each day of use?
2. For Total Residual Chlorine, is a check standard
Yam'
No
anal zed each day of use?
Y
3. Is the air calibration of the DO meter performed
(Les�
No
each day of use?
�"
4. For Settleable Solids, is 1 lifer of sample
Yes
No
settled for 1 hour?
5. Is the temperature measuring device calibrated
(YaP
No
annually against a certified thermometer?
fi. For Conductivity, is a calibration standard
Yes
No
analyzed each day of use?

IV. Documentation:
1.
Is the date and time that the sample was collected documented?
(Kej�
No
2.
Is the sample site documented?
a
No
3.
Is the sample collector documented?
p
No
4.
Is the analysis date and time documented?
y
es
No
5.
nal st sign the documentation?
Did the analyst g
0e.
No
6.
Is record of calibration documented?
Yes
No
7.
For Settleable Solids, is sample volume and
No
1 hour time settling time documented?
(Si
8. For Temperature, is the annual calibration of
the measuring device rdocumented?
Yes No
Please submit a copy of this completed form to the Laboratory Certification Program.
DWQ Lab Certification
Chemistry Lab
Courier # 52-01-01
FIELD INSPECTOR CHECKLIST REV. 04/23/2002

Burlington Industries, Inc.
Mrs. Valery Stephens
NC DENR - Water Quality/Point Source Branch
1617 Mail Service Center
Raleigh, NC 27699-1617
Subject: Renewal Application
NPDES Permit NCO043320
Burlington Industries -Richmond Plant
Richmond County
Dear Mrs. Stephens:
0
Executive Offices
PO Box 21207
Greensboro, North Carolina 27420
August 29,2003
SEP -'
Attached is the renewal application for Burlington Industries -Richmond Plant, NPDES Permit NC0043320.
Our current NPDES permit expires on February 29, 2004.
The data used for this application, except for the priority pollutant analysis, was from calendar year
2002. The priority pollutant analysis was performed from samples taken in 2003. Water usage and the
subsequent effluent discharge volumes were noticeably lower for 2002 due to soft business conditions.
The average daily production levels listed in Form 2C III.0 are also lower than in the past. We expect
business conditions to improve in the future resulting in increased production levels and effluent
discharge levels returning closer to our permit limits.
Considering our past excellent performance on the quarterly toxicity tests, Burlington Industries would
request a reduction of frequency for the toxicity test on our renewed permit.
Please call me at 336-379-2955 if you have any questions.
Sincerely,
Scott Townson
Corporate Staff Environmental Engineer
Richmond NPDES Renewal
doc

1 M Jr. A.
BURLINGTON INDUSTRIES _
RICHMOND PLANT '
WATER USE SCHEMATIC
0.02SMGD
consumption (held in cloth)
O.yr MGD . PROCESS
0% recycle
0.112-MGD )mP4 SANITARY
RICHMOND 0-573M
COUNTY
WATER
�SMGD BOILER
lowl FEEDWATER
0.392 MGD
O.O1ZMGD
0.007 MGD>_
to atmos.
o.otZ MGD
o.o.4g M
AC COOLING TOWERS to atmc
�. �z5 MGD310- NONCONTACT COOL.,NG
a
r
FlowS 6Ased a,"J
YcAA Zook AVE4AJt S .
002 EFFLUENT
O•L194 MGD WWTP 0.494 MGD
001 EFFLUENT
TO HITCHCOCK
CREEK
0.061 MGD
TO HITCHCOCK
CREEK

G
SAND BEDS
DIGESTER AERATION BASINS
CZAR [ FI ERS
FIGURE 2: PLANT LAYOUT

SLUDGE MANAGEMENT PLAN
Attached is a memo from Laidlaw Environmental Services agreeing to accept our sludge
for proper disposal when necessary. The Burlington Industries - Richmond Plant
generates very little sludge due to the nature of the plant's production processes.

a2/ig99 +5:35 803-214-5797 LAIDLAW PAGE 32
ffffffA9ffffA9
EA/VJR' 0N,A0jVMTAL
AV, lA'V/C6S lNC.
July 2, 1998
Paul Smart
Burlington Industries
Richmond Plant
P.O. Box 250
Cordova, NC 28330-0250
Dear mac. Smart:
ELUAGF Mi4pJjgG_E1tj&VT PLqnl
This letter is to inform you that Safety Kleen's , former Laidlaw Environmental Services,
Pinewood, Soutb,Carolina facility, will be able accept your sludge waste stream
providing all conditions, contingencies and regulations have been satisfied. See below
Saf.:ty-Kleen (Pinewood), Inc., formerly Laidlaw Environmental Services of South Carolina has
the appropriate permits in place as required under 40 CFR 264.1 Z (b) to manage hazardous
waste materials. The Pinewood South Carolina facility is a secure, RCRA Subtitle C landfill
operating under z Part B permit issued on March 1994 expiring March 1999- The facility's EPA
Identification Number is SCD070375985. Additionally we are permitted to landfill non-
hazardous, non RCRA wastes.
Waste material that has been treated to meet land disposal restrictions is acceptable as well as
material that requires treatment. The Pinewood South Carolina facility is capable of treating
hazardous wastes by stabilization with pozzolanic reagents. Our stabilization facility is
completely enclosed with air handling equipment that prevems the release of particulates to the
atmosphere, even if the waste material is extremely dusty.
A Laidlaw profile sheet is required for all waste to be disposed of at the facility. Additionally, we
cannot accept any material for treatment that exceeds 500 ppmfor volatile hazardous
constituents.
Our transportation group is fully licensed to haul hazardous waste materials in North Carolina.
The transportation division EPA Identification Number is SCD987574647• The insurance transportation
customer service number is 800-537-8478. They can provide certificates of p
ermit
information as needed.
Please feel free to call the Pinewood Customer Service ,Department (1800 445 2290) at any
time with questions or comments.
Sincerely,
ark A. Rhodes
1301 Ggrvais Street. Suite 300 (28201) Post office Box 11393 (29211) Columbia. South Carolina
Phone [phone]