WQ0001077_Final Permit_19980420

State of North Carolina
Department of Environment
and Natural Resources
Division of Water Quality
James B. Hunt, Jr., Governor
Wayne McDevitt, Secretary
A. Preston Howard, Jr., P.E., Director
April 20, 1998
Mr. Robert H. sCala, Vice President
Finetex Incorporated
P.O. Box 164
Spencer, NC 28159
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NORTH CAROLINA DEPARTMENT OF
ENVIRONMENT AND NATURAL RESOURCES
Subject: Permit No. WQ0001077
Finetex Incorporated, Spencer Facility
Wastewater Spray Irrigation
Rowan County
Dear Mr. sCala:
In accordance with your application received February 23, 1998, we are forwarding herewith Permit
No. WQ0001077, dated April 20, 1998, to Finetex Incorporated for the construction and continued operation
of the subject wastewater treatment and spray irrigation facilities.
This permit shall be effective from the date of issuance until March 31, 2003, shall void Permit No.
WQ0001077 issued September 12, 1997, 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 limitations 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, P.O. Drawer 27447, Raleigh, NC
27611-7447. Unless such demands are made this permit shall be final and binding.
If you need additional information concerning this matter, please contact Mr. Randy Kepler at (919)
733-5083 extension 544.
Sincerely' '
A. Preston Howard, Jr., P.E.
cc: Rowan County Health Department
Mooresville Regional Office, Water Quality Section
Mooresville Regional Office, Groundwater Section
Bob Cheek, Groundwater Section, Central Office
Technical Assistance and Certification Unit
Non -Discharge Compliance/Enforcement Unit
PO Box 29535. Raleigh, North Carolina 27626-0535 Telephone [phone] Fax [phone]
An Equal Opportunity Affirmative Action Employer 50% recycled110% 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, 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 gallon effluent holding tank, a pump station with dual 120 GPM spray irrigation pumps, a 4 acre
spray irrigation field with movable spray irrigation pipes and nozzles: and the
construction and operation of a 20,000 gallon storage tank, two 30 GPM irrigation pumps and seven 37,000
square foot irrigation zones; to serve
Finetex Incorporated's Spencer Facility, with no discharge of wastes to the surface waters, pursuant to the
application received February 23, 1998, 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 September 12, 1998, and shall be subject to the following specified conditions and
limitations:
L PERFORMANCE STANDARDS
Upon completion of construction and prior to operation of this permitted facility, 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. If this project is to be completed in phases and partials certified, you shall
retain the responsibility to track further construction approved under the same permit, and shall
provide a final certificate of completion once the entire project has been cam leted. Mail the
Certification to the Non -Discharge Permitting Unit, P.O. Box 29535, Raleigh, NC 27626-0535,
2. The Mooresville Regional Office, telephone number 704-663-1699, shall be notified at least forty-
eight (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.

3. 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
theist 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
3 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.
6. 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.
Ih OPERATION AND MAINTENANCE REQUIREMENTS
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 8A .0202. The ORC of the facility must visit each Class I facility at
least weekly and each Class 11, 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 SA .0202 Once the facility is classified, the
Permittee must submit a letter to the WPCSOCC which designates the operator in responsible
charge within thirty days after the wastewater treatment facilities are 50% complete.
3. 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.
Adequate measures shall be taken to prevent wastewater runoff from the spray field.
6. The facilities shall be effectively maintained and operated as a non -discharge system to prevent
the discharge of any wastewater resulting from the operation of this facility.
IF)

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 4 acre
spray irrigation site.
The application rate shall not exceed a cumulative loading of 29.12 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 sites.
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 (I b.Jacrelyr.) Crop PAN (lb./acre/yr.)
Alfalfa
Bermuda Grass (Hay, Pasture)
Blue Grass
Corn (Grain)
Corn (Silage)
Cotton
Fescue
200
Forest (Hardwood & Softwood)
75
220
Milo
100
120
Small Grain (Wheat, barley, oats)
100
160
Sorghum, Sudex (Pasture)
180
200
Sorghum, Sudex (Silage)
220
70
Soybeans
200
250
Timothy, Orchard, & Rye Grass
200
If the approved wastewater 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), then
the second crop shall receive an application of nutrients at a rate of no greater than 50
lbs/acre/yr. 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 application rate exceed 300 Lbs. PAN per acre per year.
b. Cumulative Metal Loadings (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
9. No type of wastewater other than that from Finetex Incorporated's Spencer Facility shall be
sprayed onto the irrigation area.
10, No traffic or equipment shall be allowed on the disposal area except while installation occurs or
while normal maintenance is being performed.
11. 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.
12. Freeboard in the aeration basins shall not be less than two feet at any time.
13. An acceptable pH must be maintained in the soil, greater than 6.0, on all land application sites to
insure optimum yield for the crop specified below. The agronomist shall provide information on
the pH best suited for the specified crop and the soil type.
14. No root or leaf crops for public consumption shall be raised on these sites.
3

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. Adequate records shall be maintained by the Permittee 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 Ioadings of plant available nitrogen (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 March, July and November for the following parameters:
Cadmium
Copper
Lead
Nickel
Zinc
Total Chromium
pH
MBAS
Oil and Grease
Phenol
Residual Chlorine
TSS
NH3 as N
COD
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 I1I 3) on Form NDMR-I shall be submitted
on or before the last day of April, August and December. All information shall be submitted to
the following address:
NC Division of Water Quality
Water Quality Section
Non -Discharge Compliance/Enforcement Unit
Post Office Box 29535
Raleigh, North Carolina 27626-0535
A representative annual soils analysis (Standard Soil Fertility Analysis) shall be conducted on
each spray field and the results maintained on file by the Permittee for a minimum of five years.
The Standard Soil Fertility Analysis shall include, but is not necessarily limited to, the following
parameters:
Acidity
Calcium
Copper
Magnesium
Cation Exchange Capacity
Manganese
Percent Hurn is Matter
pH
Phosphorus
Base Saturation (by calculation)
Potassium
Sodium
Zinc

l�
6. Noncompliance Notification:
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 o» 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 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.
GROUNDWATER REQUIREMENTS
Within sixty days of permit issuance, the permittee shall submit two original copies of a scaled
topographic map (scale no greater than 1 ":100') signed and sealed by a professional engineer or a
state licensed land surveyor that indicates all of the following information:
a. the location and identity of each monitoring well,
b. the location of the waste disposal system,
c. the location of all property boundaries,
d. the latitude and longitude of the established horizontal control monument,
e. the relative elevation of the -top of the well casing (which shall be known as the "measuring
point"), and
f. the depth of water below the measuring point at the time the measuring point is established.
The survey shall be conducted using approved practices outlined in North Carolina General
Statutes Chapter 89C and the North Carolina Administrative Code Title 21, Chapter 56. The
surveyor shall establish a horizontal control monument on the property of the waste disposal
system and determine the latitude and longitude of this horizontal control monument to a
horizontal positional accuracy of +1- 10 feet. All other features listed in a. through e. above shall
be surveyed relative to this horizontal control monument. The positional accuracy of features
listed in a. through e. above shall have a ratio of precision not to exceed an error of closure of 1
foot per 10,000 feet of perimeter of the survey. Any features located by the radial method will be
located from a minimum of two points. Horizontal control monument shall be installed in such a
manner and made of such materials that the monument will not be destroyed due to activities that
may take place on the property. The map shalt also be surveyed using the North American Datum
of 1983 coordinate system and shall indicate the datum on the map. All bearings or azimuths shall
be based on either the true or NAD 83 grid meridian. If a Global Positioning System (GPS) is
used to determine the latitude and longitude of the horizontal control monument, a GPS receiver
that has the capability to perform differential GPS shall be used and all data collected by the GPS
receiver will be differentially corrected.
The maps and any supporting documentation shall be sent to the Permits and Compliance Unit,
Groundwater Section, P.O. Box 29578, Raleigh, NC, 27626-0578.

2. The six existing monitoring wells, MW-1, MW-2, MW-3, 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)
Volatile Organic Compounds - In November only using one of the following:
Groundwater Condition IV.2 continued on the next page.....
(A) Standard Method 6230D, PQL at 0.5 ug/L or less
(B) Standard Method 621 OD, 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
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 704-663-1699, 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/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
Unit, P.O. Box 29578 Raleigh, N.C. 27626-0578 on or before the last working day of the month
following the sampling month.
3. 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)(1).

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.
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.
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 pen -nit 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.
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).

The Permittee, at least six (b) 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.
Permit issued this the Twentieth day of April, 1998
NORTH CA 71NAENVIRONMENTAL MANAGEMENT COMMISSION
A. Preston Howard, Jr., P.E., Director
Division of Water Quality
By Authority of the Environmental Management Commission
Permit Number WQ0001077

Permit No. WQ0001077
April 20, 1998
ENGINEER'S CERTIFICATION
Partial Final
1, , 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.
April 17, 1998- Construction of a 20,000 gallon storage tank, two 30 GPM irrigation pumps and seven 37,000
square foot irrigation zones
9

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