NC0004626_PERMIT ISSUANCE_20090724

NPDES DOCUNEHT SCANNIM6 COVER SHEET
NPDES Permit:
NC0004626
Document Type:
Permit Issuance
Wasteload Allocation
Authorization to Construct (AtC)
Permit Modification
Speculative Limits
Staff Report
Instream Assessment (67B)
Environmental Assessment (EA)
Permit
History
Jules 24, 2009
Document Date:
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content on the z*ever=e eiae

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NCDENR
North Carolina Department of Environment and Natural Resources
Beverly Eaves Perdue
Governor
Ms. Brigette Tinsley
PPG Industries Fiber Glass Products, Inc.
P.O. Box 949
Lexington NC, 27293
Dear Ms. Tinsley,
Division of Water Quality
Coleen H. Sullins Dee Freeman
Director Secretary
Jul), 24, 2009
Subject- Issuance of NPDES Permit NCO004626
Lexington Plant
Davidson County
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 October 15, 2007 (or as subsequently amended).
This final permit includes no major changes from the draft permit sent to you on May 20; 2009.
Please note that this discharge ultimately flows to High Rock lake, which is listed as impaired on the 303(d)
list for chlorophyll -a due to excessive nutrient inputs. A TAIDL is currently in progress, and nutrient limitations are
a potential future requirement.
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.
1617 Mail Service Center, Ralel North Carolina 27699-1617
Locat}en: 512 N Salisbury St. Raleigh, North Carolina 27604 One
Phone. [phone] FAX: [phone] Customer Service: 1-877-623-6748 North Carolina
Internet: v,rww.ncrraterquality.org �atura!!r�
An Equal Opportunity y Alfir+native Action employer

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 Sergei Chcrnikov at
telephone number [phone].
)SKerely,
en H. Sullins
cc: US EPA, Marshall Hyatt
WSRO-Surface Watcr Protection
NPDES File
Central Files
1517 Mail Service Center, Raleigh, North Carolina 27699-1617
Location: 512 N. Salisbury St. Ralegh, North Carolina 27604 One
Phone, 919-807-63001 FAX: [phone] Customer Service:1-877.623.6748 North Carolina
Internet www,newaterquality.org
An Equal Opportunity l Affirmative Action Employer AlitiurallY

Permit NCO004626
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,
PPG Industries Fiber Glass Products, Inc.
is hereby authorized to discharge wastewater from a facility located at
Lexington Manufacturing Facility
New Jersey Church Road
Lexington
Davidson County
to receiving waters designated as North Potts Creek in the Yadkin -Pee Dee River Basin in
accordance with effluent Iimitations, monitoring requirements, and other conditions set forth
in Parts I, II, III, and IV hereof.
This permit shall become effective September 1, 2009.
This permit and authorization to discharge shall expire at midnight on May 31, 2014.
Signed this day July 24, 2009.
I(A4
Cole H. Sullins, Director
��ision of Water Quality
By Authority of the Environmental Management Commission

Permit NC0004626
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.
PPG Industries Fiber Glass Products, Inc. is hereby authorized to:
1. Continue to operate an existing 0.6 MGD wastewater treatment facility consisting of the
following components:
• Mechanical bar screen
• Comminutor
• Equalization basin
• Chemical mixing tanks
• Primary clarifier
• Nutrient addition
• Dual aeration basins
• Final clarifiers
• Sodium hypochlorite with chlorine contact chamber
• De -chlorination system
• Backup clarifier system
• Dual activated carbon adsorption units with pH adjustment
• Backwash equalization basin
• Belt dewatering press
• SIudge holding
The facility is located at PPG's Lexington manufacturing facility on New Jersey Church
Road in Lexington, Davidson County.
2. Discharge from said treatment works at the location specified on the attached map into
North Potts Creek currently classified C waters in the Yadkin -Pee Dee River Basin.

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Discharge location
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PPG industries/ Lexington Facility — NCO004626 Facility
Location ' �a
USGS Quad Name: Southmont lat.: 35044'18"
Receiving Stream: North Potts Creels Long.: 80019'32"
Stream Class: C NOt to SCALE
Subbasin: Yadkin -Pee Dee 03-07-04 North

Permit NC0004626
A. (1) EFFLUENT LIMITATIONS AND MONITORING REQUIREMENTS
During the period beginning on the effective date of the permit and lasting until expiration, the Permittee is
authorized to discharge wastewater treatment plant effluent from outfall serial number 001, Such discharges
shall be limited and monitored by the Permittee as specified below:
.PARAMETER
,LIMITS.n
. , :' ' `
,, MONITOihING REQUIREMENTS
Monty•
Daily;
Measurement
;Sample
`sample
Average
Maximum .
Fre uenc
T e° F;
a Location'
Flow
0.6 MGD
Continuous
Recording
Influent or
Effluent
BOD, 5 day, 20°C
A ril 1 - October 31
157 poundslday
314 pounds/day
2/Month
Composite
Effluent
BOD, 5 day, 20°C
November 1 -- March 31
314 pounds/day
630 pounds/day
2/Month
Composite
Effluent
Total Suspended Solids
105 pounds/day
168 pounds/day
2/Month
Composite
Effluent
(April 1 - October 31
Total Suspended Solids
146 pounds/day
292 pounds/day
2/Month
Composite
Effluent
November 1 - March 31
NH3-N
Weekly
Composite
Effluent
Oil and Grease
30.0 mglL
60.0 mglL
2/Year
Grab
Effluent
Fecal Coliform
200I100 mL
4001100 mL
2/Month
Grab
Effluent
(geometric mean
Total Residual Chlorine'
28.0 pg1L
Weekly
Grab
Effluent
Temperature
Weekly
Grab
Effluent
Total Kjeldahl Nitrogen (TKN)
Weekly
Composite
Effluent
NO2+ NO3
Weekly
Composite
Effluent
Total Phosphorus
Weekly
Composite
Effluent
pH
> 6.0 and < 9.0 standard units
Weekly
Grab
Effluent
Chronic Toxicity
Quarterly
Composite
Effluent
Notes:
1. Facility shall report all effluent TRC values reported by a NC certified laboratory including field certified.
However, effluent values below 50 ktg /L will be treated as zero for compliance purposes.
2. Chronic Toxicity (Ceriodaphnia) P/F at 48%; February, May, August, and November; See condition A(2) of
the Supplement to Effluent Limitations and Monitoring Requirements portion of this permit.
There shall be no discharge of floating solids or -foam visible in other than trace amounts.

Permit NC0004626
A. (2) CHRONIC TOXICITY PASS/FAIL PERMIT LIMIT (Quarterly)
The effluent discharge shall at no time exhibit observable inhibition of reproduction or significant mortality to Ceriodaphnia
dubia at an effluent concentration of 48 %.
The permit holder shall perform at a minimum, urrr� rtert monitoring using test procedures outlined in the "North Carolina
Ceriodaphnia Chronic Effluent Bioassay Procedure," Revised February 1998, or subsequent versions or "North Carolina Phase
11 Chronic Whole Effluent Toxicity Test Procedure" (Revised -February 1998) or subsequent versions. The tests will be
performed during the months 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 If 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 If 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 THP313
for the Chronic Value. Additionally, DWQ Form AT-3 (original) is to be sent to the following address:
Attention: NC DENR / DWQ / Environmental Sciences Section
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.
If the Permittee monitors any pollutant more frequently then required by this permit, the results of such monitoring shall be
included in the calculation & reporting of the data submitted on the DMR & all AT Forms submitted.
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.

Chernikov, Sergei
I -- - II I I I II ■ I III II ■ II�III III AAA I �
From: [e-mail]
Sent: Tuesday, June 02, 2009 8:45 AM
To: [e-mail]
Subject: NC0004626, PPG Industries
EPA has reviewed this permit and has no comments.

Winston-Salem Journal
Advertising Affidavit
Winston-Salem Journal
P.0 Box 3159
Winston-Salem, NC 27102
NCDENRIDWQ/POINT SOURCE BRANCH
ATTN: DINA SPRINKLE
1617 MAIL SERVICE CENTER
RALEIGH, NC 27699-1617
Account Number
3376309
Date
May 22, 2009
Date Category Description Ad Size Total Cost
05/22/2009 legal Notices PUBLIC NOTICE North Carolina Environment 2 x 63 L 433.75
PUBLIC NOTICE
North Carolina Environmental
Management Commission/NPDES unit
1617 Mall Service Center
Rnlelgh NC 27699-1617
Notice o1♦ Intent to here a
NPOES Wastewater PermN
The North Carolina Environmental Management
Commission proposes to issue a NPDES wastewater
discharge permit to the person(s) listed below.
Media General Operations, Inc.
Publisher of the
Winston-Salem Journal
Forsyth County
Written comments 3q0 dIngdaysys after the publish date the proposed permit
will he accepted untilil30 d
Before the undersigned, a Notary Public of Forsyth County, North Carolina, duly
Division of
of this audit. The Director of the public
Water Quality (owp) may hold a public hearing
there be degree in-
commissioned, qualified, and authorized b law to administer oaths, personally appeared
q y p y pp
should a significant of public
terest. Please mal! comments and/ar Information
D.H. Stanfield, who by being duly sworn deposes and says: that he is Controller of the
requests to DWo at the above address. Interested
persons may visit the Dwo at 512 N. Salisbury
Winston-Salem Journal, engaged in the publishing of a newspaper known as Winston-Salem
Street, Rai el h, NC to review Information an file.
Additional information on NPOES permits and this
Journal, published, issued and entered as second class mail in the City of Winston-Salem, in
notice may be found an our website: www.ncwater
quality.org, or by calling (9191607-6304,
said County and State: that he is authorized to make this affidavit and sworn statement: that
Inc requested
Industries it N Glans Prioduct%6for Lexington
renewal
renewal of perms NC6004626 far Lexington Plant In
the notice or other legal advertisement, a true copy of which is attached hereto, was
Davidson County; this facility discharge Is treated
r to North Potts Creek.
Industrial wastewater Nor
published in the Winston-Salem Joumal on the following dates:
p g
The Clty of 1Nlns n-Salem requested renewal of
permit NC00a6011 for the Neilson WTP In Forsyth 05/22/2009
County. This permitted discharge Is treated filter-
backwash wastewater to an unnamed tributary to
Muddy Creek In thr Yadkin -Per Dee River Basin.
The Clty of Winston-Salem requested renewal of
permit NC007M1 for the R.A. Thomas WTP In For-
and that the said newspaper in which such notice, paper document, or legal advertisement
syth county. This permitted discharge Is treated
Iilter-backwash wastewater to Salem Creek In the
was published was, at the time of each and every such publication, a newspaper meeting all
Yadkln-Pee Dee River Basin.
the requirements and qualifications of Section 1-597 of the General Statutes of North
The City of Wlnstom5alam requested renewal of
permit N4-,007ol4,e tar Muddy Creek WWTP In for-
Carolina and Was a qualified newspaper within the meaning of Section 1-597 of the General
syth County; this facility discharge 13 treated mu-
nklpai wastewater to Yadkin River, Yadkin River
Basin.
Statutes of North Carolina.
The City of Yylmtan-Salem requested renewal of
sYth County; ermit this for
dischargArchie e Iswtreated WTP in mu•
n�ciral wastewater to Salem Creek. Yadkin River
Bas n.
This 22th day of May, 2009 n
The Town of Boonville has requested renewal of
pprrmlt NC.020931 for the Bcanvlllr WWTP In
Vadkln County. This permitted discharge is treated
domestic wastewater to the Tanyard Creek In the
(signahrre of perso i makn g IC�aVfl)
Yadkin Pee -Dee River Basin.
wsl: May zz, zoos
Sworn to and subscribed before me, this 22th day of May, 2009
My Commission expires 2-010
09291RU11[,111 :0117411►1■HlIll #I:/_1►1I&W011111

NCDENR/DWQ
FACT SHEET FOR NPDES PERMIT DEVELOPMENT
PPG Industries Fiber Glass Products, Inc
NC0004626
t Y& :l S. �' VE12 r�' ���3 �� � ,Facili Informafiio..n�
1. FaciIi Name:
PPG Industries Fiber Glass Products, Inc
(2.) Permitted FIow (MGD):
0.6 MGD
(6.) County:
Davidson
(3.) Facility ass:
Class III
1 (7.) Regional Office:
Winston-Salem
(4.) Pretreatment Program
N/A
(8.) USGS Topo.Quad:
D17NE, E17NE
(5.) Permit Status:
Renewal
(9.) USGS Quad Name:
Southmont
Streain,Characteristics..,: ,ram t , ,�:,
P
(1.) Receiving Stream:
North Potts Creek
(7.) Drainage Area (mi2):
11.5
(2.) Sub -basin:
03-07-04
(8.) Summer 7Q10 (cfs):
1.0
(3.) Stream Index Number:
12-112
(9.) Winter 7Q10 (cfs):
2.2
(4.) Stream Classification:
C
(10.) 30Q2 (cfs):
(5.) 303(d) Status:
Not listed
(11.) Average Flow (cfs):
11.0
(6.) 305(b) Status:
N/A
(12.) IWC %:
48
1.0 Proposed Chafes Incorporated into Permit Renewal
Monitoring frequencies for BOD, TS5, and Fecal Coliforms were reduced from weekly
to 2/Month (Oil and Grease was reduced from Monthly to 2/year) in response to the permittee's
request and based on the EPA Interim Guidance for Performance -Based reductions of NPDES
perinit Monitoring Frequencies.
2.0 Summary
PPG Industries Fiber Glass Products, Inc operates a fiberglass fiber manufacturing facility in
Lexington, NC. The Lexington plant currently concentrates the bulk of its fiberglass yarn
manufacturing on the textile industry as well as the printed circuit board industry.
Manufacturing begins with glass raw materials including limestone, silica, boron, clay and
fluorspar. These raw materials are blended in powder form and added to melt furnaces. The
batch -melt furnaces, operating at 2800°F transform the batch into molten glass. The molten glass
is then drawn from the furnaces through electrically heated platinum bushings into continuous
fibers. These fibers are gathered into strands and either spooled or chopped into specified
lengths. Water sprays cool the glass and keep strand contact points clean during the winding
process.
PPG's Lexington facility discharges through a single permitted outfall, 001. This outfaH is from
the wastewater treatment plant and receives the following kinds of wastewater:
➢ Sanitary (American Children's Home) ➢ Process W W
r➢ In -plant sanitary ➢ Non -contact cooling water
➢ Boiler feed ➢ SIudge dewatering
As part of a settlement agreement reached in 1995, instream monitoring is not a current permit
requirement. The facility was required to monitor at 10 instream stations once during the

NPDES Permit Fact Sheet — 05/ 15/09
Page 2
PPG Industries/ Lexington Facility
NCO004626
summer of 1995 and once in 1996. Monitored parameters were DO, temperature, conductivity,
pH, total phosphorus, nitrate, nitrite, ammonia and TKN. The monitoring was completed as
required and is not proposed with this renewal.
Current effluent limitations for BODs and TSS appear to be based on water quality protection and
not on federal guidelines. Extensive research was conducted during the 1998 renewal to
determine if any federal guidelines exist for such -a manufacturing operation. Neither textile nor
glass guidelines applies to PPG's process. A review of the WLA file indicates that the limits
installed in 1983 were based on BPJ.
The facility discharges to North Potts Creek. North Potts is tributary to High Rock Lake and is
not listed on the State's 303(d) list
3.0 Comj2liarice Summary"
The facility has an excellent compliance history, during the review period (01/2005 through
03/2009) the facility had no Notices of Violations. The last compliance evaluation inspection
conducted on 02/19/2008 concluded that facility is "well maintained and operated".
4.0 WET Test
PPG Industries has been consistently passing WET test during the review period. Chronic P/F @
48% (also recommended with renewal).
5.0 ._ Proposed Schedule for Permit Issuance
Draft Permit to PuM blic Notice: May 20, 2009 (est.)
Permit Scheduled to Issue: July 141, 2009 (est.)
6.0 - - - State Contact Information
If you have any questions on any of the above information or on the attached permit, please
contact Sergei Chernikov [phone]. ;
Regional_ Office Comments:
Regional Recommendation by:
Signature Date

Via Certified Mail
Return Receipt Requested
November 25, 2008
Mrs. Dina Sprinkle
NC DENR
Division of Water Quality
Point Source Branch
1617 Mail Service Center
Raleigh, NC 27699-1617
PPG Industries
PPG Industries Fiber Glass Products, Inc
473 New ,jersey Church Road
Post Office Box 949
Lexington, North Carolina 27293
Brigette Tinsley
Environmental Engineer
Phone [phone] ext 317
Fax [phone]
E-Mail [e-mail]
r ' _
fl f; t
DEC
-• tom„ . r i
Re: Renewal of NPDES Permit NCO004626
PPG Industries Fiber Glass Products, Inc., Lexington, Davidson County, NC
Dear Mrs. Sprinkle:
We are pleased to enclose an original, signed NPDES Permit Renewal Application package
along with the two required photo copies. This is for the PPG industries Fiber Glass Products,
Inc. facility in Lexington, NC. We are requesting the re -issuance of NPDES Permit No.
NC0004626. The primary SIC Code for facility operations is 3229-Pressed and Blown Glass -not
elsewhere classified. The wastewater outfall, Outfall 001, is located at latitude 35 degrees, 44
minutes, 18 seconds, by longitude 80 degrees, 19 minutes, 32 seconds with the receiving water
being North Potts Creek.
There have been several improvements to our wastewater management program since our last
NPDES permit renewal. These include:
1. We have added a belt dewatering press to dewater our primary and secondary sludge
residuals;

-2-
2. We have terminated our land application permit and now the dewatered residuals are
disposed of in the Davidson County Landfill;
3. We have added a de -chlorination system; and
4. We have added a backup clarifier system.
As part of this permit renewal package, we have included:
1. Cover letter;
2. Introduction;
3. EPA Form 1;
4. EPA Form 2C;
5. Narrative description of the sludge management plan;
6. Analytical data; and
7. Performance based reduced permit monitoring frequency.
The data presented in Form 2C Section V is based on plant operating data for the period June
2007 to May 2008 and special analysis conducted by Pace Analytical Services Inc. The
performance based reduced permit monitoring frequency data is based on 24 months (June 2006
— May 2008). Copies of the reports on the special analysis have been provided in the package
(Appendix A). The plant operating data is from monthly DMR submittals.
Please feel free to contact me if there are any questions regarding this submittal.
Sincerely,
7Br'gette ins eynvironmental Engineer
Attachment
cc: David Segers
Pat Pride — GTC

Certification
I certify that I am familiar with the information contained in this application and that to the best of my
knowledge and belief such information is true, complete, and accurate.
Printed Name of Person Signing:—_Jadai 12outlait
Title: / iGR ft Laf lfKC_G 11 cter
JI-zS-0
(Signature of Applicant) (Ddte Signed)
North Carolina General Statute 143-215.6 b (i) provider, that:
Any person who knowingly makes any false statement, representafion, or certification in any applicatian, record, report, plan or
other document filed or required to be maintained under Article 21 or regulations of the Environmental Management Commission
implementing that Article, or who falsifies, tampers with or knowingly renders inaccurate any recording or monitoring device or
method required to be operated or maintained under Article 21 or regulations of the Environmental Management Commission
implementing that Article, shall be guilty of a misdemeanor punishable by a fine not to exceed $25,000, or by imprisonment not to
exceed six months, or by both. (18 U.S.C, Section 1001 provides a punishment by a fine of not more than $25,000 or imprisonment
not more than 5 years, or both, for a similar offense.)
t� i�' DEC 2 2;'° '`

INTRODUCTION
PPG Industries Fiber Glass Products, Inc. (PPG) operates a Fiber Glass manufacturing facility
in Lexington, North Carolina. This facility operates under the existing NPDES Wastewater
Permit Number NCO004626 which expires on May 31, 2009. This permit allows the facility
to discharge treated wastewater at 0.6 million gallons/day to Outfall 001. In addition to PPG's
Fiber Glass Manufacturing operation, there is the sanitary wastewater from the American
Children's Home, which is located near the PPG site and discharges approximately 4,000
gallons per day to the PPG wastewater treatment plant for treatment. Additional details and
clarification for several items relevant to this permit application are highlighted below.
1. Sample Reporting and Averaging
Sample reporting and averaging was provided in Form 2C as per NC DENR DWQ's
"Directions for Completing Monthly Monitoring Reports" dated September 1, 2000.
These instructions provide guidelines with respect to rules for reporting and averaging less
than detectable " < " values. (e.g., a sample result with a value of less than the detectable
limit is considered to equal "zero" when calculating monthly and long-term arithmetic
averages). Also per NC DENR DMR reporting guidelines, fecal coliform monthly and
long-term averages were calculated using a geometric mean.
2. Signature Authority
There will be no change requested in signature authority for monthly monitoring report
requirements. Signature authority for monthly monitoring reports as a "Duly Authorized
Representative" per 15A NCAC 2B.0506(b)(2)(D), will remain unchanged and is delegated
to the person holding the title of Maintenance Manager.

SLUDGE MANAGEMENT PLAN
PPG Industries generates both primary and secondary sludge residuals as part of the industrial
wastewater treatment process. The primary sludge results from a lime precipitation process
and the secondary sludge is generated in an activated sludge biological treatment plant.
A schematic of the sludge management system is presented in Figure 1. The waste primary
and secondary sludge is dewatered on a belt filter press.
The belt dewater press is a-U.S. Filter model BPC-1600-7C. This is a 1.6 meter process with
a solids processing capacity of 9.6 dry tons/day (3,494 dry tons/yr). This unit will dewater the
solids from the stabilization decant/thickener. The dewatered solids drop into a container and
are hauled to the Davidson County Landfill. There is more than adequatecapacity to handle
all of the sludge generated onsite. PPG has been approved to haul the dewatered sludge to the
Davidson County Landfill. A copy of the landfill approval of this disposal is attached
(Attachment A).
PPG typically operates this unit on a 3 day/week basis for 8 hours/day (24 hr/week operation).
This mode of operation can handle 100% of the solids generated. The system could be
operated up to 7 days/week at 20 hr/day operation (140 hrs/week). Therefore, the system uses
less than 20 percent of the available dewatering capacity.
The PPG wastewater treatment system is designed to provide operating flexibility. Therefore,
PPG can adjust to changing waste loads and changes in environmental regulations.
B9;TW:
7

WASTE PRIMARY STABILIZATION
SLUDGE
DECANT/ THICKENER
November 13, 200E 3:06 35 p.m.
Drawing: 25930P02.D WG
CANT TO WWTP
-ADWORKS
--R
BELT
DEWATERING
PRESS
�
aeeeseee
00 00
HAUL TO
LANDFILL
SLUDGE MANAGEMENT SYSTEM
FLOW SCHEMATIC
PPG INDUSTRIES
LEXINGTON, NORTH CAROLINA
SCALE AS NOTED APPROVED BY R. STEIN DRAWN BY; K.S.
DATE NOVEMBER 2008
Z DESIGNED BY R. STEIN REVISED
ROJECT
PN 2 59 MBJ 9305-J MOt�ROM • + R T�� NC 2B27o DRAWING NO.
FIGURE 1

c e
Unwood.
cp,
ALL' I
Lo
iL
Ar
4
SCALE: 1. 24000
1 1/2 0 1 MILE
1000 0 2000 4000 6000 80DO FEET
PPG INDUSTRIES FIBER PRODUCTS, INC. FIGURE 1
N LEXINGTON, NORTH CAROLINA SITE LOCATION MAP
AffA "fir -
REFERENCE: ENVIRONMENTAL INC
BASE MAPS TAKEN FROM NATIONAL GEOGRAPHIC A IVArml & IL Ahm
SEAMLESS USGS TOPOGRAPHIC MAPS ON CD—ROM AEI PROJECT No. N259-17
SOFTWARE. TOPO CURRENT AS OF 2001.
FORM 2C.I.A

•��f<Mid,
DAVIDSON COUNTY
INTEGRATED SOLID WASTE MANAGEMENT
1242 OLD US HWY 29/70
TEL# [phone] THOMASVILLE N.C. 27360 FAX# [phone]
September 8, 2006
PPG Industries
Brigette M Tinsley
Environmental Engineer
473 New Jersey Church Road
Post Office Box 949
Lexington, NC 27293
RE: Approval Letter for Dewatered Sludge Waste
Dear Brigette,
We have contacted the NC Department of Environment and Natural Resources and have checked to make
sure that the Davidson County Landfill can accept the Dewatered Sludge generated from your Industry.
At this present time, the Davidson County Solid Waste Department will approve / and accept the new waste
stream (Dewatered Sludge) generated from PPG Industries. The tapping fee will be $10 per cubic yard.
In the advent that local, state, or the Federal Iaws were to change in reference to disposal of this waste, this
agreement letter will be void.
Thank you,
Charles Brushwood
ISW Director
CB: abj

0.022 MGD 0.022 MGD
BOILER FEED
0.273 MGD
PROCESS
WATER
0.248 MGD
AMERICAN
CHILDRENS
HOME
0,004 MGD
CITY OF 0,535 MGD 0.347 MGD WASTEWATER
0.347 MGD + STORM WATER
LEXINGTON TREATMENT
EVAPORATION 0.188 MGD PLANT DISCHARGE
STORMWATER
o.os3 MGD
MAX.
0.197 MGD Q.034 MCD 0.004 MGD
NON CONTACT
COOLING
SLUDGE
0.043 MGD 0.043 MGD
SANITARY FORM 2C Il.a
FLOW DIAGRAM
PPG
LEXINGTON, NORTH CAROLINA
SCALE NOT TO SCALE APPROVED BY DRAWN BY: ,LK,S.
DAZE NOVEMBER 2008 1 DESIGNED 9Y REVISED
Nlo'+ernb4r 13, 200S 301:3a PROJECT NUM9ER ■ /1 A%AMPw y DRFIGURE 2INC NO
.p,m. A�`ii
IV�fl`. Aw
Drawing: 25930P03.DWG - 259`30 �9305-j MOr:ROE RO. CHARLOTTE, NC 28Z70

Form 2C.I1.13
Attached Stormwater Calculations
PPG Industries Fiber Glass Products Inc. — Lexington, NC
Stormwater flow calculated using; the Rational Method from the Stale of North Carolina Erosion
and Sediment Control Planning and Design Manual, December 1, 1993.
The rational formula is:
Q=CiA
where:
Q = peak rate of runoff
C = runoff coefficient
i = average intensity of'rainfall
A = drainage area
i = 0.15 inches/hour
A = 43,425 ft2 to treatment system
Q= (0.95)(0.15 in/hr)(1 ft/12 in)(24 hr/day)(43,425 17t)
Q= 12,376 ft3/day
Q= 92,573 GPD
13

Form 2C.II.B.3.a.
Attached Description of Wastewater Treatment Process
PPG Industries Fiber Glass Products Inc. — Lexington, NC
The wastewater is generated from the fiberglass manufacturing operation, the boiler
operations, non contact cooling blow down, plant sanitary wastewater and the sanitary
wastewater from the American Children's Home. The wastewater is treated in a 0.6 MGD
treatment facility. A process flow schematic is attached (Figure 2). The wastewater treatment
processes includes screening of the process wastewater and comminutors for the sanitary
wastewaters.' All wastes are (lien equalized, chemically treated using lime and ferric chloride
and settled in a primary clarifier. The primary clarifier effluent is treated in an activated
sludge system followed by a chlorine contact chamber, dechlorination and activated carbon
columns. Currently 100% of the treated effluent is discharged to North Potts Creek.
The primary and secondary sludges are combined in a stabilization decant/thickener followed
by belt press dewatering. The decant can be returned to the wet well or treated separately in
one of the activated sludge aeration basins. The dewatered sludge is transported to the
Davidson County Landfill.
14

CHEMICAL CHLORINE
8AR EQUALIZATION ADDITION PRIMARY ACTIVATED SLUDGE SECONDARY ACTIVATED CARBON
HYDRASIEVE SCREEN TANKS REACTOR CLARIFICATION AERATION BASINS CLARIFICATION C� ANK T COLUMNS
TANKS
FERRIC
PROCESS
WASTE
PPG AND
CHILDREN",
SANITARY
STABILIZATION
DECANT/THICKENER
LEGEND
WASTEWATER
- - - - SLUDGE
24, 2008 10: 3& 27 a.m.
Drawing: 259 30PO I .DWG
DISCHARGE
TO HIGH
ROCK LAKE
BELT FILTER HAUL TO
PRESS LANDFILL
FORM 2c II.B.3.a
PROCESS FLOW SCHEMATIC
PPG INDUSTRIES FIBERGLASS PRODUCTS, INC.
LEXINGTON, NORTH CAROLINA
SCALE NOT TO SCALE APPROVED BY : DRAWN BY: J.K.S.
DATE NOVEMBER 2043
DESIGNED BY : REv15Eo
PROJECT NUNHER MARC--
/ C-. DRAWING NO,
N 259 - 30 305—J ►IONROE RE). CHARLOTTE. NC 28270 FIGURE 3

Performance -Based Reduced Permit Monitoring Frequency
U.S. EPA guidelines provide for a performance based reduction of NPDES permit monitoring
frequencies. In conjunction with our NPDES Permit Renewal Application Form 2C, PPG
Industries Fiber glass Products Inc. is requesting reductions in the monitoring frequency of
several effluent characteristics. The PPG Industries, Lexington, NC facility continues to
maintain high standards for wastewater treatment and takes pride in its excellent historical
performance in regard to its NPDES permit compliance. Based on a parameter -by -parameter
analysis and two-year composite averages versus our Monthly Average Discharge Limitations
we are requesting a reduction in monitoring frequencies per the USEPA's Interim Guiclance for
Performance -Based Reduction of NPDES Permit Monitoring Frequencies. The two-year time
period is from June 2006 to May 2008. The following table lists the parameters of interest, our
two-year composite averages for each parameter (based on the attached NPDES Effluent Data
Logs in the analytical monitoring section), our Monthly Average Discharge Limits, and the Ratio
of PPG's Two -Year Composite Average to the corresponding Monthly Average Discharge
Limit:
Effluent Characteristics
Two -Year
NPDES Monthly
Two -Year Composite
Composite
Average
vs. Monthly Average
Average
Discharge
Discharge Limit
Limitation
BOD, 5-Day, 20°C
1.4 lb/day
157 lb/day
0.9%
(Apr] 1 1 —October 31)
BOD, 5-Day, 20°C
7.1 lb/day
314 lb/day
2.3%
(November I — March 31)
Total Suspended Solids
1.3 lb/day
105 lb/day
1.2%
(April I —October 31)
Total Suspended Solids
3.5 lb/day
146 lb/day
2.4%
(November I — March 31)
Oil and Grease
1.1 mg/L
30 mg/L
3.7%
Fecal Coliform
11.51100 ml
200/100 ml
5.75%
(Geometric Mean)
30

Using the ratio of Two -Year Composite Averages to the Monthly Average Discharge Limits
from the table above, and comparing to Table 1 (Attached) in the Interim Guidance for
Performance -Based Reduction of NPDES Permit Monitoring Frequencies, PPG is eligible and is
requesting the following reductions in monitoring frequency:
Effluent Characteristics
Current Monitoring
Eligible Monitoring
Frequency
Fre uenc
BOD, 5-Day, 20°C
Weekly
1/2 mo.
(April 1 — October 31)
BOD, 5-Day, 20°C
Weekly
1/2 mo.
(November 1 — March 31)
Total Suspended Solids
Weekly
1/2 mo.
(April 1 — October 31)
Total Suspended Solids
Weekly
1/2 mo.
(November 1 — March 31)
Oil and Grease
Monthly
1/6 mo.
Fecal Coll form
Weekly
1/2 mo.
(Geometric Mean)
31

PERFORMANCE-BAno REnUCTIOH OF MONITORING F REQUE�CtE,C
include pollutants which pose heightened risks to human or environmental health,
such as highly toxic or bioaccumulative compounds.
3) Parameter -by -Parameter Performance History
At a' minimum, the two most. recent years of monthly average effluent data
representative of current operating conditions for- the parameter at the particular
outfall will be used to calculate the long term average discharge rate for use in Table
• The baseline monitoring. frequencies in Table I of this guidance will normally be
considered the level of monitoring in the existing effective NPDES permit. It is
important to recognize that permittees that receive monitoring frequency reductions in
accordance with -Table I or Table 2. are still expected to take all appropriate measures
to control both the average level of pollutants of concern in their discharge (mean) as
well as the variability of such parameters in the discharge -(variancej, regardless of
any reductions in monitoring frequencies granted from the baseline levels. Reliance
on monitoring the discharge at a reduced frequency as the sole means of tracking and
controlling the discharge could increase the risk of violations.
Table 1
Ratio of Long Term Effluent Average
to Monthly Average Limit
Baseline
Monitories
75- 6'Fa
6 - %
4 -25 % '
<2 %
7/wk
5/wk
4/wk
3/wk
1/wk
6/wk
4/wk
3/wk
2/wk
1 /wk
5/wk
4/wk
3/wk
2/wk
I/wk
4/wk
3/wk
2/wk
Uwk
llwk
3/wk
3/wk'
2/wit
I/wk
I/.wk
2/wk
2/wk
I/wk
21mo
1/moo
I/wk
1/wk
1/wk
2/mo
1/2mos
2/month
2/mo
2/mo
2/mo
1/quarter
1/Inonth
I/mo
limo
I/quarter
1/6mos
Note: See above eligibility requirements.
WrF.Rim GUIDANCt Al-KIL" 1996 -5-