WQ0001077_Final Permit_20000623

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
June 23, 2000
Mr. Robert H. Scala, Vice President
Finetex Incorporated
PO Box 164
Spencer, North Carolina 28159
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NORTH CAROLINA DERARTMENT OF
ENVIRONMENT AND NATURAL RESOURCES
Subject: Permit No. WQ0001077
Spencer Facility
Wastewater Spray Irrigation
Rowan County
Dear Mr. Scala:
In accordance with your application received August 25, 1999, we are forwarding herewith Permit No.
WQ0001077, dated June 23, 2000, to Finetex Incorporated for the construction of an expansion to the two
aeration basins and the continued operation of the subject wastewater treatment and spray irrigation facilities.
Please pay particular attention to Conditions VI. 9 through VI. 13 regarding evaluation of the
wastewater treatment system.
This permit is being issued to modify the wastewater treatment and disposal system by expanding he
aerations basins. This permit shall be effective from the date of issuance until March 31, 2003, shall void
Permit No. WQ0001077 issued April 20, 1998 and shall be subject to the conditions and limitations as
specified therein. Please pay particular attention to the monitoring requirements in this permit. Failure to
establish an adequate system for collecting and maintaining the required operational information will result in
future compliance problems.
If any parts, requirements, or Iimitations contained in this permit are unacceptable, you have the right
to request an adjudicatory hearing upon written request within thirty (30) days following receipt of this permit_
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, NC
27699-6714. Unless such demands are made this permit shall be final and binding.
One set of approved plans and specifications is being forwarded you. If you need additional
information concerning this matter, please contact Sue Homewood at (919)3--5083 extension 502.
Sincer ,
i
Kerr T. Stevens
cc: Rowan County Health Department
MacConnell & Associates, P.C.
Mooresville Regional Office, Water Quality Section
Mooresville Regional Office, Groundwater Section
Groundwater Section, Central Office
Technical Assistance and Certification Unit
Non -Discharge Compliance/Enforcement Unit
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

NORTH CAROLINA
ENVIRONMENTAL MANAGEMENT COMMISSION
DEPARTMENT OF ENVIRONMENT AND NATURAL RESOURCES
RALEIGH
SPRAY IRRIGATION SYSTEM PERMIT
In accordance with the provisions of Article 21 of Chapter 143, General Statutes of North Carolina as amended, and
other applicable Laws, Rules, and Regulations
PERMISSION IS HEREBY GRANTED TO
Finetex Incorporated
Rowan County
FOR THE
continued operation of a 18,000 GPD spray irrigation treatment and disposal facility consisting of an influent flow
measurement/recorder, manual bar screen, a clarifier, a flocculation tank with mixer, a polymer feed system, dual
115,000 gallon aeration basins in series with mechanical aerators and lined with stone and clay, an 8,000 galls
effluent holding tank, a pump station with dual 120 GPM spray irrigation pumps, a four acre spray irrigation field wits,
movable spray irrigation pipes and nozzles, a 20.000 gallon effluent storage tank, two 30 GPM irrigation pumps and a
second spray field with seven 37,000 square foot (approximately 6 acres) irrigation zones. and the
construction to expand the two aeration basins to 252,536 gallons and 247,156 gallons, both expansions to be clay
lined; to serve
Finetex Incorporated's Spencer Facility, with no discharge of wastes to the surface waters, pursuant to the application
received August 25, 1999, and in conformity with the project plan, specifications, and other supporting data
subsequently filed and approved by the Department of Environment and Natural Resources and considered a part of
this permit.
This permit shall be effective from the date of issuance until March 31, 2003, shall void Permit No. WQ0001077
issued April 20, 1998, and shall be subject to the following specified conditions and limitations:
I. PERFORMANCE STANDARDS
Upon completion of construction of the expansion of the aeration basins, a certification must be received
from a professional engineer certifying that the permitted facility has been installed in accordance with this
permit, the approved plans and specifications, and other supporting materials. Mail the Certification to the
Non -Discharge Permitting Unit, Division of Water Quality, 1617 Mail Service Center, Raleigh, NC
27699-1617.
2. The Mooresville Regional Office, telephone number 704-663-1699 shall be notified at least forty-eig
(48) hours in advance of operation of the installed facilities so that an in -place inspection can be made.
Such notification to the regional supervisor shall be made during the normal office hours from 8:00 a.m.
until 5:00 p.m. on Monday through Friday, excluding State Holidays.

The spray irrigation facilities shall be effectively maintained and operated at all times so that there is no
discharge to the surface waters, nor any contamination of ground waters which will render them
unsatisfactory for normal use. In the event that the facilities fail to perform satisfactorily, including the
creation of nuisance conditions or failure of the irrigation area to adequately assimilate the wastewater, the
Permittee shall take immediate corrective actions including those actions that may be required by the
Division of Water Quality (Division), such as the construction of additional or replacement wastewater
treatment and disposal facilities.
4. The issuance of this permit shall not relieve the Permittee of the responsibility for damages to surface or
groundwaters resulting from the operation of this facility.
5. The residuals generated from these treatment facilities must be disposed in accordance with General
Statute 143-215.1 and in a manner approved by the Division.
b. Diversion or bypassing of the untreated wastewater from the treatment facilities is prohibited.
7. The following buffers shall be maintained:
a) 400 feet between wetted area and any residence or places of public assembly under separate
ownership,
b) 150 feet between wetted area and property lines,
c) 100 feet between wetted area and wells,
d) 100 feet between wetted area and drainageways or surface water bodies,
e) 50 feet between wetted area and public right of ways,
f) 100 feet between wastewater treatment units and wells, and
g) 50 feet between wastewater treatment units and property lines.
Some of the buffers specified above may not have been included in previous permits for this waste
treatment and disposal system. These buffers are not intended to prohibit or prevent modifications, which
are required by the Division, to improve performance of the existing treatment facility. These buffers do,
however, apply to modifications of the treatment and disposal facilities which are for the purpose of
increasing the flow that is tributary to the facility. These buffers do apply to any expansion or
modification of the spray irrigation areas and apply in instances in which the sale of property would cause
any of the buffers now complied with, for the treatment and disposal facilities, to be violated. The
applicant is advised that any modifications to the existing facilities will require a permit modification.
H. OPERATION AND MAINTENANCE REQUIREMENTS
1. The facilities shall be properly maintained and operated at all times.
2. Upon classification of the facility by the Water Pollution Control System Operators Certification
Commission (WPCSOCC), the Permittee shall employ a certified wastewater treatment plant operator to
be in responsible charge (ORC) of the wastewater treatment facilities. The operator must hold a certificate
of the type and grade at least equivalent to or greater than the classification assigned to the wastewater
treatment facilities by the WPCSOCC. The Permittee must also employ a certified back-up operator of the
appropriate type and grade to comply with the conditions of 15A NCAC 8G .0202. The ORC of the
facility must visit each Class I facility at least weekly and each Class II, III, and IV facility at least daily,
excluding weekends and holidays, and must properly manage and document daily operation and
maintenance of the facility and must comply with all other conditions of 15A NCAC 8G .0202.
A suitable year round vegetative cover shall be maintained.
4. Irrigation shall not be performed during inclement weather or when the ground is in a condition that will
cause runoff.
5. Adequate measures shall be taken to prevent wastewater runoff from the spray field.

5
91
Adequate measures shall be taken to prevent wastewater runoff from the spray field.
The facilities shall be effectively maintained and operated as a non -discharge system to prevent tf..
discharge of any wastewater resulting from the operation of this facility.
The application rate shall not exceed a cumulative loading of 28.6 inches over any twelve (12) month
period at an instantaneous application rate not to exceed 0.25 inches per hour on the four acre spray
irrigation site.
The application rate shall not exceed a cumulative loading of 26 inches over any twelve (12) month period
at an instantaneous application rate not to exceed 0.25 inches per hour on the seven 37,000 square foot
spray irrigation site.
Wastewater application rates shall not exceed:
(a) Annual Loading Limits:
1. 0.45 pounds of cadmium per acre per year.
2. The Plant Available Nitrogen (PAN) per acre per year shall be limited * as follows:
Crop PAN 0b./acre/yr.) Crop PAN_Clb./acre/yam
Alfalfa 200 Forest (Hardwood & Softwood) 75
Bermuda Grass (Hay, Pasture) 220 Milo 100
Blue Grass 120 Small Grain (Wheat, barley, oats) 100
Corn (Grain) 160 Sorghum, Sudex (Pasture) 180
Corn (Silage) 200 Sorghum, Sudex (Silage) 220
Cotton 70 Soybeans 200
Fescue 250 Timothy, Orchard, & Rye Grass 200
If the approved land application sites are to be double cropped (i.e., a crop in the spring and a
second crop in the fall, with BOTH crops to receive wastewater residuals), then the second crop
shall receive an application of nutrients at a rate of no greater than 50 lbs/acrelyr. This practice will
be allowed as long as the second crop is to be harvested. If the second crop is to be planted for
erosion control only, and is to be tilled into the soil, then no wastewater residuals shall be applied to
these fields because the nitrogen will essentially be returned to the soil. At no time shall the total
PAN a Iication rate exceed 300 lbs. PAN per acre per year.
(b) Cumulative Metal Laodings (based on CEC of the spray irrigation sites):
Lifetime Loadings (lbs/acre)
Parameter
CEC < 5
CEC 5 - 15
CEC > 15
Lead
500
1000
2000
Zinc
250
500
1000
Copper
125
250
500
Nickel
125
250
500
Cadmium
4.5
9
18
10_ No type of wastewater other than that from Finetex Incorporated's Spencer Facility shall be sprayed onto
the irrigation area.
11. No traffic or equipment shall be allowed on the disposal area except while installation occurs or whil
normal maintenance is being performed.
12. Public access to the land application sites shall be controlled during active site use. Such controls may
include the posting of signs showing the activities being conducted at each site.

14. An acceptable pH must be maintained in the soil, greater than 6.0, on all land application sites.
15. No root or leaf crops for public consumption shall be raised on these sites.
III. MONITORING AND REPORTING REQUIREMENTS
Any monitoring (including groundwater, surface water, soil or plant tissue analyses) deemed necessary by
the Division to insure surface and ground water protection will be established and an acceptable sampling
reporting schedule shall be followed.
2. The Permittee shall maintain adequate records tracking the amount of wastewater disposed. These records
shall include, but are not necessarily limited to, the following information:
a. date of irrigation,
b. volume of wastewater irrigated,
c. field irrigated,
d. length of time field is irrigated,
e_ continuous weekly, monthly, and year-to-date hydraulic (inches/acre) loadings for each field,
f, weather conditions,
g. maintenance of cover crops,
h. annual loading of PAN, Cadmium, and lime additions, and
i. cumulative loadings of Lead, Zinc, Copper, Nickel and Cadmium.
3. The effluent from the subject facilities shall be monitored by the Permittee at the point prior to irrigation
every month for the following parameters:
Influent flow, continuous and daily
Cadmium
Copper
Lead
Nickel
Zinc
Total Chromium
PH
MBAS
Oil and Grease
Phenol
Residual Chlorine
TSS
NH as N
TKN
NO as N
PAN (by calculation)
COD
BOD
Flows by-passed to the Spencer wastewater collections stem
4. Three (3) copies of all operation and disposal records (as specified in condition 111 2) on Form NDAR-1
shall be submitted on or before the last day of the following month. Three (3) copies of all effluent
monitoring data (as specified in condition 111 3) on Form NDMR-1 shall be submitted on or before the last
day of each month. All information shall be submitted to the following address:
NC Division of Water Quality
Water Quality Section
Non -Discharge Compliance/Enforcement Unit
1617 Mail Service Center
Raleigh, North Carolina 27699-1617
4

A representative soils analysis (Standard Soil Fertility Analysis) shall be conducted annually on each spray
field and the results maintained on file by the Permittee for a minimum of five years. The Standard Sc
Fertility Analysis shall include, but is not necessarily limited to, the following parameters:
Acidity
Calcium
Copper
Magnesium
Lead
Nickel
b. Noncompliance Notification:
Manganese
Percent Humic Matter
pH Zinc
Exchangeable Sodium Percentage
Cadmium
Cation Exchange Capacity
Potassium
Sodium
Phosphorus
Chromium
Base Saturation (by calculation)
The Permittee shall report by telephone to the Mooresville Regional Office, telephone number 704-663-
1699 as soon as possible, but in no case more than 24 hours or on the next working day following the
occurrence or first knowledge of the occurrence of any of the following:
a. Any occurrence at the wastewater treatment facility which results in the treatment of significant
amounts of wastes which are abnormal in quantity or characteristic, such as the dumping of the
contents of a sludge digester; the known passage of a slug of hazardous substance through the facility;
or any other unusual circumstances.
b. Any process unit failure, due to known or unknown reasons, that render the facility incapable of
adequate wastewater treatment such as mechanical or electrical failures of pumps, aerators,
compressors, etc.
c. Any failure of a pumping station, sewer line, or treatment facility resulting in a by-pass directly to
receiving waters without treatment of all or any portion of the influent to such station or facility.
d. Any time that self -monitoring information indicates that the facility has gone out of compliance with
its permit limitations.
Persons reporting such occurrences by telephone shall also file a written report in letter form within five
(5) days following first knowledge of the occurrence. This report must outline the actions taken or
proposed to be taken to ensure that the problem does not recur.
IV. GROUNDWATER REQUIREMENTS
1. Existing monitor wells MW-1, MW-2 and MW-3 shall be sampled every March, July and November for
the following parameters:
Water Level pH
Iron Total Dissolved Solids (TDS)
Lead Total Organic Carbon (TOC)
Volatile Organic Compounds - In November only using one of the following:
(A) Standard Method 6230D, PQL at 0.5 ug/L or less
(B) Standard Method 6210D, PQL at 0.5 ug/L or less
(C) EPA Method 8021, Low Concentration, PQL at 0.5 ug/L or less
(D) EPA Method 8260, Low Concentration, PQL at 0.5 ug/L or less
(E) Another method with prior approval by the Groundwater Section Chief
For monitoring limits, please refer to 15A NCAC 2L, Groundwater Classifications and Standards.

Any method used must meet the following qualifications:
(1) A laboratory must be DWQ certified to run any method used.
(2) The method used must, at a minimum, include all the constituents listed in Table VIII of
Standard Method 6230D.
(3) The method used must provided a PQL at 0.5 ug/L or Iess which must be supported by
laboratory proficiency studies as required by the DWQ Laboratory Certification Unit. Any
constituents detected above the MDL but below the PQL at 0.5 ug/L must be qualified
(estimated) and reported.
If any volatile organic compounds are detected by the methods listed, then the Mooresville Regional
Office Groundwater Supervisor, telephone number 704-663-1699 must be contacted immediately for
further instructions regarding any additional follow-up analyses required. The results of all initial and
follow-up analyses must be submitted simultaneously.
The measurement of water levels must be made prior to sampling for the remaining parameters. The depth
to water in each well shall be measured from the surveyed point on the top of the casing.
The measuring points (top of well casing) of all monitoring wells shall be surveyed to provide the relative
elevation of the measuring point for each monitoring well.
If TOC concentrations greater than 10 mg/I are detected in any downgradient monitoring well, additional
sampling and analysis must be conducted to identify the individual constituents comprising this TOC
concentration. If the TOC concentration as measured in the background monitor well exceeds 10 mg/l,
this concentration will be taken to represent the naturally occurring TOC concentration. Any exceedances
of this naturally occurring TOC concentration in the downgradient wells shall be subject to the additional
sampling and analysis as described above.
The results of the sampling and analysis must be received on Form GW-59 (Groundwater Quality
Monitoring: Compliance Report Form) by the Groundwater Section, Permits and Compliance Lint,
1636 Mail Service Center Raleigh, N.C. 27699-1636 on or before the last working day of the month
following the sampling month.
2. Existing monitor wells MW-4, MW-5 and MW-6 shall be sampled every March, July and November for
the following parameters:
Water Level pH
Iron Total Dissolved Solids (TDS)
Lead Total Organic Carbon (TOC)
Chloride MBAS
Copper Phenol
Zinc
Volatile Organic Compounds - In November only using one of the following:
(A) Standard Method 6230D, PQL at 0.5 ug/L or less
(B) Standard Method 6210D, PQL at 0.5 ug/L or less
(C) EPA Method 8021, Low Concentration, PQL at 0.5 ug/L or less
(D) EPA Method 8260, Low Concentration, PQL at 0.5 ug/L or Iess
(E) Another method with prior approval by the Groundwater Section Chief
For monitoring limits, please refer to 15A NCAC 2L, Groundwater Classifications and Standards.
Any method used must meet the following qualifications:
(1) A laboratory must be DWQ certified to run any method used.

(2) The method used must, at a minimum, include all the constituents listed in Table VIII of
Standard Method 6230D.
(3) The method used must provided a PQL at 0.5 ug/L or less which must be supported by
laboratory proficiency studies as required by the DWQ Laboratory Certification Unit. Any
constituents detected above the MDL but below the PQL at 0.5 ug/L must be qualified
(estimated) and reported.
If any volatile organic compounds are detected by the methods listed, then the Mooresville Regional
Office Groundwater Supervisor, telephone number 704-663-I699 must be contacted immediately for
further instructions regarding any additional follow-up analyses required. The results of all initial and
follow-up analyses must be submitted simultaneously.
The measurement of water levels must be made prior to sampling for the remaining parameters. The depth
to water in each well shall be measured from the surveyed point on the top of the casing.
The measuring points (top of well casing) of all monitoring wells shall be surveyed to provide the relative
elevation of the measuring point for each monitoring well.
If TOC concentrations greater than 10 mg/1 are detected in any downgradient monitoring well, additional
sampling and analysis must be conducted to identify the individual constituents comprising this TOC
concentration. If the TOC concentration as measured in the background monitor well exceeds 10 mg/l,
this concentration will be taken to represent the naturally occurring TOC concentration. Any exceedances
of this naturally occurring TOC concentration in the downgradient wells shall be subject to the additional
sampling and analysis as described above.
The results of the sampling and analysis must be received on Form GW-59 (Groundwater Quality
Monitoring: Compliance Report Form) by the Groundwater Section, Permits and Compliance Uni ,
1636 Mail Service Center Raleigh, N.C. 27699-1636 on or before the last working day of the month
following the sampling month.
Any additional groundwater quality monitoring, as deemed necessary by the Division, shall be provided.
4. The COMPLIANCE BOUNDARY for the disposal system is specified by regulations in 15A NCAC 2L,
Groundwater Classifications and Standards. The Compliance Boundary is for the disposal system
constructed after December 31, 1983 is established at either (1) 250 feet from the waste disposal area, or
(2) 50 feet within the property boundary, whichever is closest to the waste disposal area. An exceedance
of Groundwater Quality Standards at or beyond the Compliance Boundary is subject to immediate
remediation action in addition to the penalty provisions applicable under General Statute 143-
215.6A(a)(I).
In accordance with 15A NCAC 2L, a REVIEW BOUNDARY is established around the disposal systems
midway between the Compliance Boundary and the perimeter of the waste disposal area. Any exceedance
of standards at the Review Boundary shall require remediation action on the part of the permittee.
V. INSPECTIONS
Adequate inspection, maintenance, and cleaning shall be provided by the Permittee to insure proper
operation of the subject facilities.

2. The Permittee or his designee shall inspect the wastewater treatment and disposal facilities to prevent
malfunctions and deterioration, operator errors and discharges which may cause or lead to the release of
wastes to the environment, a threat to human health, or a nuisance. The Permittee shall keep an inspection
log or summary including at least the date and time of inspection, observations made, and any
maintenance, repairs, or corrective actions taken by the Permittee. This log of inspections shall be
maintained by the Permittee for a period of three years from the date of the inspection and shall be made
available upon request to the Division or other permitting authority.
Any duly authorized officer, employee, or representative of the Division may, upon presentation of
credentials, enter and inspect any property, premises or place on or related to the disposal site or facility at
any reasonable time for the purpose of determining compliance with this permit; may inspect or copy any
records that must be maintained under the terms and conditions of this permit, and may obtain samples of
groundwater, surface water, or leachate.
VI, GENERAL CONDITIONS
This permit shall become voidable unless the facilities are constructed in accordance with the conditions of
this permit, the approved plans and specifications, and other supporting data.
2. This permit is effective only with respect to the nature and volume of wastes described in the application
and other supporting data.
3. This permit is not transferable. In the event there is a desire for the facilities to change ownership, or there
is a name change of the Permittee, a formal permit request must be submitted to the Division accompanied
by an application fee, documentation from the parties involved, and other supporting materials as may be
appropriate. The approval of this request will be considered on its merits and may or may not be
approved.
4. Failure to abide by the conditions and limitations contained in this permit may subject the Permittee to an
enforcement action by the Division in accordance with North Carolina General Statute 143-215.6A to 143-
215.6C.
5. The issuance of this permit does not preclude the Permittee from complying with any and all statutes,
rules, regulations, or ordinances which may be imposed by other government agencies (local, state, and
federal) which have jurisdiction.
6. A set of approved plans and specifications for the subject project must be retained by the Permittee for the
life of the project.
7. The annual administering and compliance fee must be paid by the Permittee within thirty (30) days after
being billed by the Division. Failure to pay the fee accordingly may cause the Division to initiate action to
revoke this permit as specified by 15A NCAC 2H .0205 (c)(4).
8. The Peri ittee, at least six (6) months prior to the expiration of this permit, shall request its extension.
Upon receipt of the request, the Commission will review the adequacy of the facilities described therein,
and if warranted, will extend the permit for such period of time and under such conditions and limitations
as it may deem appropriate.
Within six months of permit issuance the permittee shall evaluate the existing method of measuring
influent flow and submit a report proposing modifications as needed to the Mooresville Regional Office,
Water Quality Section, 919 North Main Street, Mooresville, North Carolina 28115.

10. The permittee within six months of permit issuance shall install a flow metering device to measure the
flow to the Spencer wastewater collection system.
11. The permittee shall complete all recommendations from the Soil Scientist report dated January 12, 2000
and shall submit a final report to the Mooresville Regional Office, Water Quality Section, 919 North Main
Street, Mooresville, North Carolina 28115.
12. Field 2 zones 4, 6, & 7, shall not be used for spray irrigation until written approval is received from the
Mooresville Regional Office —Water Quality Section.
13. Before this permit can be renewed the permittee will be required to submit a complete wastewater
treatment system evaluation. In addition, an Operation and Maintenace Plan shall be developed for the
wastewater treatment and spray irrigation system. This evaluation shall include but not be limited to:
• Evaluation of expansion to aeration basins to control overflow and/or discharges.
• Determination if the stone and clay liner of the existing portion of the aeration basins is sufficient to
protect groundwater and/or surface water.
• Evaluation of the ability of existing mechanical aerators to properly treat the volume of waste in the
aeration basins.
• The effectiveness of the existing wastewater treatment system to produce effluent of a quality to be
easily assimilated by land disposal.
• Evaluation of foaming problems in the aeration basins.
• The possible need for aeration in the 20,000 gallon storage tank so that effluent does not go septic
prior to irrigation.
Permit issued this the, 23`d day of June, 2000
NORTH OL1NA IR ENTAL MANAGEMENT COMMISSION
-Kerr T. Stevens, Director
Division of Water Quality
By Authority of the Environmental Management Commission
Permit Number WQ0001077
9

Permit No. WQ0001077
May 12, 2000
ENGINEER'S CERTIFICATION
Partial Final
I, , as a duly registered Professional Engineer in the State of North
Carolina, having been authorized to observe (periodically, weekly, full time) the construction of the project,
Project Name
Location and County
for the Permittee hereby state that, to the best of my abilities, due care and diligence was used in the observation of the
construction such that the construction was observed to be built within substantial compliance and intent of this permit,
the approved plans and specifications, and other supporting materials.
Signature
Date
Registration No.
10

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