NCG500321_Regional Office Historical File Pre 2018

ROY COOPER
Governor
MICHAEL S. REGAN
Secretaw
S. JAY`ZIMMERMAN
Director
Tony Setzer
Shuford Yarns
2815 1st Avenue SW
Hickory, NC.28602
SUBJECT: Compliance Evaluation Inspections
Dudley Shoals Plant
Permit No: NCG500321 and NCO035211
Caldwell County
Dear Mr. Setzer:
On January 25, 2017, I conducted a Compliance Evaluation Inspection at the subject facility for Permits
NCG500321 and NCO035211. The facility appeared to be in compliance with both permits. There are items,
however, that need your attention to maintain compliance. Please refer to the enclosed inspection reports for
comments related to these items. If you or your staff have any questions, please call me at 828-296-4500.
Sincerely,
�- r
Linda Wiggs
Environmental Senior Specialist
Asheville Regional Office
Enc. Inspection Reports for NCG500321 & NCO035211
cc: MSC 1617-Central Files -Basement
Asheville Files
G:\WR\WQ\Caldwell\Wastewater\General\Non-contact NCG50\Shuford-NCG500321\CEI.Jan2017.Ltr.docx
G:\WR\WQ\Caldwell\Wastewater\Minors\Dudley Shoals Plant 35211\CEI.Jan2017.Ltr.docx
State of North Carolina I Environmental Quality I Water Resources
2090 U.S. Highway 70 Swannanoa, NC 28778
828 296 4500

United States Environmental Protection Agency
Form Approved.
EPA Washington, D.C.20460
OMB No. 2040-0057
Water Compliance InspectionReport
Approval expires 8-3-98
Section A: National Data System Coding (i.e., PCS)
Transaction Code NPDES yrlmo/day Inspection Type Inspector FacType
1 2 U. 3 I NC0035211 I11 12 17/01/25 17 181 C I 19 LGj 201
_1
211 11 1 I I I I I I 11 I I 1 I I I I 1 1 1 I I 1 I I I 1 1 I I 1 1' I 11 I 1 I "'F f
Inspection
Work Days Facility Self -Monitoring Evaluation Rating B1 CA ----- ­—Reserved
72 [ ,J 73 I II I 11
70 L_71 L] I
80
Section B: Facility Data
Name and Location of Facility Inspected (For Industrial Users discharging to POTW, also include
Entry Time/Date
Permit Effective Date
POTW name and NPDES permit Number)
10:30AM . 17/01/25
15/06/01
Dudley Shoals Plant
5100 Burns Rd
Exit Time/Date
Permit Expiration Date
Granite Falls NC 28630
11:30AM 17/01/25
20/03/31
Name(s) of Onsite Representative(s)/Titles(s)/Phone and Fax Number(s)
Other Facility Data
111
Name, Address of Responsible Official/Title/Phone and Fax Number
Contacted
Mark E Hawes,PO Box 1530 Hickory NC 286031530//828-322-2700/8283255387
Yes
Section C: Areas Evaluated During Inspection (Check only those areas evaluated)
Permit Operations & Maintenance ` Records/Reports Self -Monitoring Program '.
® Facility Site Review ® Effluent/Receiving Waters
.Section D: Summary of Finding/Comments (Attach additional sheets of narrative and checklists as necessary)
(See attachment summary)
Name(s) and Signatures) of In tctor(s) Agency/Office/Phone and Fax Numbers Date
Linda S Wiggs ARO WQ//828-296-4500 Ext.4653/
Daniel J Boss ARO WQ//828-296-4658/
Signature of Management Q A Reviewer Agency/Office/Phone and Fax Numbers Date
EPA Form 3560-3 (Rev 9-94) Previous editions are obsolete.
Page# 1

NPDES yr/mo/day Inspection Type (Cont.) 1
31 NC0035211 I11 12 17/01/25 17 g '
Section D: Summary of Finding/Comments (Attach additional sheets of narrative and checklists as necessary)
Present for inspection were Cecil Cline, Tony Setzer, Keith Johnson and Mike Bradshaw with Shuford
Yarns, Jerry Younce with Water Tech (ORC/Lab) and Dan Boss with DWR.
An inspection of the Non -Contact Cooling Water (NCG500321) was also performed. As noted in that
inspection report Shuford staff indicated that the Air Compressor Cooling Tower water discharges to
the Wastewater Septic/Sand filter system and not directly to the creek. This needs to be verified and
quantified.
Flows are estimated by water usage (City Water). The quantity of water being discharged through the
Cooling Water discharge pipe and the Wastewater discharge pipes is unclear. An estimate needs to '
be obtained during sampling events at each discharge pipe.
Page# 2

Permit: NCO035211 Owner - Facility: Dudley Shoals Plant
Inspection Date: 01/25/2017 Inspection Type: Compliance Evaluation
Operations & Maintenance
Yes No NA NE
Is the plant generally clean with acceptable housekeeping?
M
❑
El
El
Does the facility analyze process control parameters, for ex: MLSS, MCRT, Settleable
❑
❑
❑
Solids, pH, DO, Sludge Judge, and other that are applicable?
Comment:
Permit
Yes No NA NE
(If the present permit expires in 6 months or less). Has the permittee submitted a new
❑
❑
®
❑
application?
Is the facility as described in the permit?
0
❑
❑
El
# Are there any special conditions for the permit?
❑
❑
0
❑
Is access to the plant site restricted to the general public?
0
❑
❑
❑
Is the inspector granted access to all areas for inspection?
0
❑
❑
❑
Comment:
i
Record Keeping
i
Yes No NA NE
Are records kept and maintained as required by the permit?
®'
❑
❑
❑
Is all required information readily available, complete and current?
®
❑
❑
❑
Are all records maintained for 3 years (lab. reg. required 5 years)?
®
❑
❑
❑
Are analytical results consistent with data reported on DMRs?
®
❑
❑
❑
Is the chain -of -custody complete?
❑
❑
❑
Dates, times and location of sampling
❑
Name of individual performing the sampling
❑
Results of analysis and calibration
❑
Dates of analysis
Name of person performing analyses
❑
Transported COCs
❑
Are DMRs complete: do they include all permit parameters?
®
❑
❑
❑
Has the facility submitted its annual compliance report to users and DWQ?
❑
❑
®
❑
(If the facility is = or > 5 MGD permitted flow) Do they operate 2417 with a certified operator
❑
❑
®
❑
on each shift?
Is the ORC visitation log available and current?
❑
❑
❑
Is the ORC certified at grade equal to or higher than the facility classification?
®
❑
❑
❑
Is the backup operator certified at one grade less or greater than the facility classification?
®
❑
❑
❑
Is a copy of the current NPDES permit available on site?
®
❑
❑
❑
Page#
3

Permit: NCO035211 Owner - Facility:
Dudley Shoals Plant
Inspection Date: 01/25/2017 Inspection Type:
Compliance Evaluation
Record Keeping
Yes No NA NE
Facility has copy of previous year's Annual Report on file for review?
❑
❑
0
❑
Comment:
Septic Tank
Yes No NA NE
(If pumps are used) Is an audible and visual alarm operational?
❑
❑
®
❑
Is septic tank pumped on a schedule?
0
❑
❑
Are pumps or syphons operating properly?
❑
❑
®
❑
Are high and low water alarms operating properly?
❑
❑
®
❑
Comment: Bumgarner Septic Hauler pumps the septic tank 2/yr. The last
pumping was in September
of 2016.
Sand Filters (Low rate)
Yes No NA NE
(If pumps are used) Is an audible and visible alarm Present and operational?
❑
❑
®
❑
Is the distribution box level and watertight?
❑
❑
❑
Is sand filter free of ponding?
0
❑
❑
❑
Is the sand filter effluent re -circulated at a valid ratio?
❑
❑
®
❑
# Is the sand filter surface free of algae or excessive vegetation?
®
❑
❑
❑
# Is the sand filter effluent re -circulated at a valid ratio? (Approximately 3 to 1)
❑
❑
®
❑
Comment: The sand filter wall has been improved to avoid run on of stormwater.
The Dosing Bells were replaced in 2013.
The distribution lines are cleaned annually.
Effluent Pipe
Is right of way to the outfall properly maintained?
Are the receiving water free of foam other than trace amounts and other debris?
If effluent (diffuser pipes are required) are they operating properly?
Comment:
Yes No NA NE
®
❑
❑
❑
®❑
❑
❑
❑
❑
®
❑
Page# 4

United States Environmental Protection Agency
Form Approved.
EPA Washington, D.C.20460
OMB No. 2040-0057-
Water Compliance Inspection Report
Approval expires8-31-98
Section A: National Data System Coding (i.e., PCS)
Transaction Code NPDES yr/mo/day Inspection Type Inspector Fac Type
I,, I 2 15 I 3 I NCG500321 (11 12 17/01/25 117 181 19 Li 201 1
21111111 1111111 11-11 I II 1111 1 111111 11111111111 f6
Inspection
Work Days Facility Self -Monitoring Evaluation Rating B1 CIA -----------=- Reserved----- -----
671
_ 70 71 72 _NJ 731 75� 1 I 1 1 1 _jj
L_j
80
Section B: Facility Data
Name and Location of Facility Inspected (For Industrial Users discharging to POTW, also include
Entry Time/Date
Permit Effective Date
POTW name and NPDES permit Number)
10:30AM 17/01/25
15/12/29
Dudley Shoals Plant
5100 Burns Rd
Exit Time/Date
Permit Expiration Date
Granite Falls NC 28630
12:00PM 17/01/25
20/07/31
Name(s) of Onsite Representative(s)/Titles(s)/Phone and Fax Number(s)
Other Facility Data
Name, Address of Responsible Official/Title/Phone and Fax Number
Contacted
Mark E Hawes,PO Box 2228 Hickory NC 286032228//828-325-5428/8283255387
Yes
Section C: Areas Evaluated During Inspection (Check only those areas evaluated)
Operations:&.Maintenanc€ . Records/Reports - Seif-Monitoring Program .; ..Facility_ Site Review-
Effluent/Receiving Waters
Section D: Summary of Finding/Comments (Attach additional sheets of narrative and checklists as necessary)
(See attachment summary)
Name(s) and Signature(s) ofInspector(s) Agency/Office/Phone and Fax Numbers Date
Linda S Wiggs ARO WQ!l828-296-4500 Ext.4653/
Daniel J Boss (/2 ARO WQ1/828-296-4658/
Signature of Management Q A Reviewer Agency/Office/Phone and Fax Numbers Date
1! l6 /
EPA'Form 3560-3 (Rev 9-94) Previous editions are obsolete.
Page# 1

NPDES yr/mo/day Inspection Type (Cont.) 1
31 NCG500321 I11 12 17/01/25 17 18 ICI
Section D: Summary of Finding/Comments (Attach additional sheets of narrative and checklists as necessary)
Present for inspection were Cecil Cline, Tony Selzer, Keith Johnson and Mike Bradshaw with Shuford
Yarns, Jerry Younce with Water Tech (ORC/Lab) and Dan Boss with DWR.
Site plan reviewed is dated 3/25/1996. The site plan does not appear to be accurate any longer and
needs to be updated.
Shuford Yarn staff indicated Point A (Air Compressor Cooling Tower) on the site plan discharges to the
Wastewater Septic/Sand filter system and not directly to the creek.
Staff also indicated the Cooling components associated with Point C are directed to the treatment area
near point B on the South side of the property: and discharge to the creek after de -chlorination.
This area of the facility was inspected and staff were instructed to determine -where flows from the
concrete pipe (-18-24") were coming from and where the floor drains in the "air wash" room go.
Staff indicate the chemicals approved on the Biocide sheets are still being used, except AWT is no
longer used.
Analytical data reviewed (2015-2016) indicated compliance, however items noted below need to be
undertaken.
Flows are estimated by water usage (City Water). It is not clear how much of this water is.being
discharged through the Cooling Water discharge pipe and the Wastewater discharge pipes. An
estimate needs to be obtained during sampling events at each discharge pipe.
Total Residual Chlorine (TRC) at the cooling water effluent discharge pipe is required.
We discussed the annual maintenance of cooling equipment and the potential for a pollutant load to be
discharged during this activity, such as increased flows and concentrated chemicals/metals.
9 9 Y�
f Sampling during this-activity.should take place to evaluate if effluent limits are met. If staff find limits are'
not met during such activities, contact the inspector to discuss what measures the facility plans to put
in place to remediate pollutant load.
Page# 2

Permit: NCG500321 Owner -Facility: Dudley Shoals Plant
Inspection Date:_ 01/25/2017 Inspection Type: Compliance Evaluation
Operations & Maintenance
Yes No NA NE
Is the plant generally clean with acceptable housekeeping?
N
❑
❑
❑
Does the facility analyze process control parameters, for ex: MLSS, MCRT, Settleable
❑
❑
N
❑
Solids, pH, DO, Sludge Judge, and other that are applicable?
Comment:
Effluent Pipe
Yes No NA NE
Is right of way to the outfall properly maintained?
®
❑
❑
❑
Are the receiving water free of foam other than trace amounts and other debris?
0
❑
❑
❑
If effluent (diffuser pipes are required) are they operating properly?
❑
❑
0
❑
Comment:
Effluent Sampling
Yes No NA NE
Is composite sampling flow proportional?
❑
❑
0❑
Is sample collected below all treatment units?
❑
❑
®
❑
Is proper volume collected?
❑
❑
®
❑
Is the tubing clean?
❑
❑
®
❑
# Is proper temperature set for sample storage (kept at less than or equal to 6.0 degrees
❑
❑
®
❑
Celsius)?
Is the facility sampling performed as required by the permit (frequency, sampling type
®
❑
❑
❑
representative)?
Comment:
Upstream / Downstream Sampling Yes No NA NE
Is the facility sampling performed as required by the permit (frequency, sampling type, and ® ❑ ❑ ❑
sampling location)?
Comment:
Page# 3

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hICt3ENR
North Carolina Department of Environment and Natural Resources
Division of Water Quality
Pat McCrory Thomas A. Reeder John E. Skvarla, III
Governor Acting Director Secretary
July 3, 2013
Tony Setzer
Shuford Yarns
2815 1 st Avenue SW
Hickory, NC 28602
SUBJECT: Compliance Evaluation Inspection
Dudley Shoals Plant -Cooling Water Discharge
Permit No: NCG500321
Caldwell County
Dear Mr. Setzer:
On June 20, 2013, 1 conducted a compliance inspection associated with the cooling water
discharges at the Shuford Yarns Dudley Shoals Plant. You and Cecil Cline were present
for the inspection. The facility was found to be marginally compliant with permit
NCG500321. You will need to include the parameter Chemical Oxygen Demand (COD)
when sampling the effluent; see Footnote #4 in Part I A. (1) of your NCG500321 permit.
Please refer to the enclosed inspection report for further observations and comments. If
you or your staff have any questions, please call me at 828-296-4500.
Sincerely,
Linda Wiggs
Environmental Senior Specialist
Asheville Regional Office
Enclosure
cc: Central Files
Asheville Files
S:\SWP\Caldwell\Wastewater\General\Non-contact NCG50\Shuford-NCG500321\CEI. 6-20-2013.doc
SURFACE WATER PROTECTION — ASHEVILLE REGIONAL OFFICE One
Location: 2090 U.S. Highway 70, Swannanoa, NC 28778 NO Carolina
Phone:: ww ncwat00\FAX: org 299-7043� Naturally
Internet: www:ncwatergualitv.orp

United States Environmental Protection Agency
Form Approved.
Washington, D.C. 20460
EPA
OMB No. 2040-0057
Water Complianinp Inspection Rp-pnrt
Approval expires 8-31-98
Section A: National Data System Coding (i.e., PCs)
Transaction Code NPDES yr/mo/day Inspection Type Inspector Fac Type
1 INI 2 15 I 31 NCG500321 111 121 13/06/20 117 18I S I 19I S I 20IU
Remarks
21I1111111IIII IIJI IIIIIIIIIIII1111 IIIIIIII11111116
Inspection Work Days Facility Self -Monitoring Evaluation Rating B1 QA ----------- -------------- Reserved ----------- ----------
67 I 169 70I_I 711 I 721 NJ 73 L U 74 751 I I I I I I 180
Section B: Facility Data
Name and Location of Facility Inspected (For Industrial Users discharging to POTW, also include
Entry Time/Date
Permit Effective Date
POTW name and NPDES permit Number)
Dudley Shoals Plant
10:00 AM 13/06/20
12/08/01
Exit Time/Date
Permit Expiration Date
5100 Burns Rd
Granite Falls NC 28630
11:50 AM 13/06/20
15/07/31
Name(s) of Onsite Representative(s)/Titles(s)/Phone and Fax Number(s)
Other Facility Data
///
Name, Address of Responsible Official/Title/Phone and Fax Number
Contacted
Mark E Hawes,PO Box 2228 Hickory NC 286032228//828-325-5428/8283255387 Yes
Section C: Areas Evaluated During Inspection (Check only those areas evaluated)
Permit Operations & Maintenance 0 Records/Reports Self -Monitoring Program
Facility Site Review Effluent/Receiving Waters
Section D: Summary of Finding/Comments (Attach additional sheets of narrative and checklists as necessary)
(See attachment summary)
Name(s) and Signature(s) of Inspector(s) Agency/Office/Phone and Fax Numbers Date
Linda S Wiggs ARO WQ//828-296-4500 Ext.4653/
Signature of Management Q A Reviewer Agency/Office/Phone and Fax Numbers
�iDate
r
EPA Form 3560-3 (Rev 9-94) Previous editions are obsolete.
Page # 1

NPDES yr/mo/day Inspection Type (cont.)
3 NCG500321 I11 12, 13/06/20 117 18IS1
Section D: Summary of Finding/Comments (Attach additional sheets of narrative and checklists as necessary)
The monitoring requirement for the cooling water discharge is twice a year for the following parameters:
{Effluent Limitations and Monitoring Requirements are listed in the table in Part I A.(1) of the permit}
*Flow -estimated at the end of the discharge pipe.
*Temperature -at the end of the discharge pipe and upstream and downstream of the discharge pipe.
(See Footnote 1 in the table)
*Total Residual Chlorine (TRC)-at the end of the discharge pipe. (See Footnote 2 in the table)
*pH -at the end of the discharge pipe.
*Chemical Oxygen Demand (COD) -at the end of the discharge pipe. (See Footnote 4 in the table)
The facility has not been sampling for COD, but needs to begin sampling for this parameter with the next
sampling event. COD is required because the facility uses water treatment chemicals in their discharge.
Biocide/Chemical Treatment Worksheets 101 were approved in 2007 for CWT-501, AWT-25 and CWT-804.
Page # 2

Permit: NCG500321 Owner - Facility: Dudley Shoals Plant
Inspection Date: 06/20/2013 Inspection Type: Compliance Sampling
Operations $ Maintenance Yes No NA NE
Is the plant generally clean with acceptable housekeeping? ■ n n Cl
Does the facility analyze process control parameters, for ex: MLSS, MCRT, Settleable Solids, pH, DO, Sludge n n ■ n
Judge, and other that are applicable?
Comment:
Ve- M- ILIA WC
(If the present permit expires in 6 months or less). Has the permittee submitted a new application?
Is the facility as described in the permit?
# Are there any special conditions for the permit?
Is access to the plant site restricted to the general public?
Is the inspector granted access to all areas for inspection?
Comment:
Effluent Sampling
Is composite sampling flow proportional?
Is sample collected below all treatment units?
Is proper volume collected?
Is the tubing clean?
# Is proper temperature set for sample storage (kept at less than or equal to 6.0 degrees Celsius)?
Is the facility sampling performed as required by the permit (frequency, sampling type representative)?
Comment: Sampling shall be performed as indicated in permit under Part I A. (1).
Please pay special attention to the footnotes for the parameters listed in the table.
Yes No NA NE
nn■n
■nnn
■nnn
0 0 M 0
n n n ■
0 M 0 0
Page # 3

United States Environmental Protection Agency
Form Approved.
EPA Washington, D.C. 20460
OMB No. 2040-0057
Approval expires 8-31-98
Section A: National Data System Coding (i.e., PCS)
Transaction Code NPDES yr/mo/day Inspection Type Inspector Fac Type
1 INI 2 15 I 31 NCG500321 111 121 13/06/17 117 18I S I 19I S I 20I II
Remarks
211111111111111111111111111111 IIIIIIIIIIIIIIIIII 6
Inspection Work Days Facility Self -Monitoring Evaluation Rating 131 QA --------------------------- Reserved ----------------------
67 I 169 701 I 711 I 721 N I 73 W 74 751 I I I I I Li
Section B: Facility Data
Name and Location of Facility Inspected (For Industrial Users discharging to POTW, also include
Entry Time/Date
Permit Effective Date
POTW name and NPDES permit Number)
10:00 AM 13/06/17
12/08/01
Dudley Shoals Plant
Exit Time/Date
Permit Expiration Date
5100 Burns Rd
Granite Falls NC 28630
01:00 PM 13/06/17
15/07/31
Name(s) of Onsite Representative(s)/Titles(s)/Phone and Fax Number(s)
Other Facility Data
Name, Address of Responsible Official/Title/Phone and Fax Number
Contacted
Mark E Hawes,PO Box 2228 Hickory NC 286032228//828-325-5428/8283255387 No
Section C: Areas Evaluated During Inspection (Check only those areas evaluated)
Permit Operations & Maintenance Records/Reports 0 Self -Monitoring Program
Facility Site Review Compliance Schedules Effluent/Receiving Waters 0 Other
Section D: Summary of Finding/Comments (Attach additional sheets of narrative and checklists as necessary)
(See attachment summary)
Name(s) and Signature(s) of Inspector(s) Agency/Office/Phone and Fax Numbers Date
Linda S Wiggs ARO WQ//828-296-4500 Ext.4653/
Signature of Management Q A Reviewer Agency/Office/Phone and Fax Numbers Date
EPA Form 3560-3 (Rev 9-94) Previous editions are obsolete.
Page # 1

NPDES yr/mo/day Inspection Type 1
3I NCG500321 111 12, 13/06/17 117 18I S1
Section D: Summary of Finding/Comments (Attach additional sheets of narrative and checklists as necessary)
i
4 g
t
GIB 7 W5
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Page # 2

Permit: NCG500321
Inspection Date: 06/17/2013
Owner - Facility: Dudley Shoals Plant
Inspection Type: Compliance Sampling
Operations $ Maintenance Yes No NA NE
Is the plant generally clean with acceptable housekeeping? n n n
Does the facility analyze process control parameters, for ex: MLSS, MCRT, Settleable Solids, pH, DO, Sludge n n n
Judge, and other that are applicable?
Comment:
Yes No NA NE
(If the present permit expires in 6 months or less). Has the permittee submitted a new application?
Is the facility as described in the permit?
# Are there any special conditions for the permit?
Is access to the plant site restricted to the general public?
Is the inspector granted access to all areas for inspection?
Comment:
Effluent Sampling
Is composite sampling flow proportional?
Is sample collected below all treatment units?
Is proper volume collected?
Is the tubing clean?
# Is proper temperature set for sample storage (kept at less than or equal to 6.0 degrees Celsius)?
Is the facility sampling performed as required by the permit (frequency, sampling type representative)?
Comment:
Compliance Schedules
Is th,�'� a`cdirplikce chedullobrl'this facili
Is the faNity compfiant with�tt e permit'dr9dconditio
Comment:
Other
Comment:
n n. n
00E'0
nnpin
nnn
rnnn
Yes No NA NE
nnQrn
nnn
..E-1nnn
nntarn
n n n,�>
n,Tlnn
Yes No NA NE
nnnn
'-Q000
Yes No NA NE
Page # 3

C
Qi'Shuford
V'a1 LLB
+ F: �
30 January 2007 j I
2007
Y'
Mr. Charles H. Weaver,l
NC DENR / DW / NPDES AS !0 }
1617 Mail Service Center _ _ �W
Raleigh, North Carolina 27699-1617
RE: NCG500000 Renewal Application
Shuford Yarns, LLC, Dudley Shoals Facility
5100 Burns Road
Granite Falls, North Carolina
Certificate of Coverage (C®C) NCG500321
Enclosed, please find the complete renewal information for the referenced discharge
permit. Also enclosed are completed Biocide 101 forms along with supporting
information as required.
The Shuford Yarns, LLC, Dudley Shoals Facility (the Facility) discharges water from air
wash stations, and from cooling towers, under the referenced discharge permit. Water
treatment for the discharges is currently contracted to Elements Illustrated, Inc. The
primary water treatment chemicals are as follows:
• CWT-501 {active ingredient: Poly [oxyethylene (dimethyliminio) ethylene
(dimethyliminio) ethylene dichloride] }
• AWT-25 {active ingredient: Poly [oxyethyethylene (dimethyliminio) ethylene
(dimethyliminio) ethylene dichloride] }
• -*Wr-804 (active ingredient: Acrylic Terpolymer)
a �r
Note that the CWT-501 is used in both the cooling towers and the air washes at the
facility. AWT-25 is used is used in just the air washes. AWT-804 is only used in the
cooling towers.
To complete the Biocide 101 forms, stream flow data was obtained from the USGS. A
copy of the information provided by the USGS is attached.
1985 Tate Blvd SE, Box 54, Hickory, NC 28602
Corporate Phone: [phone] Corporate Fax: [phone]

Mr. Charles H. Weaver
30 January 2007
Page 2 of 2
Shuford Yarns understands that the new permit will include a chlorine limitation. To
comply with such a standard, steps to dechlorinate the discharge will be required. The
Facility requests that the permit specifically state that up to 18 months will be allowed to
comply with any such standard, to allow time to design and construction such
dechlorination facilities as will be required.
Finally, on 23 June 2006, an application was submitted requesting that the company
name be changed from Shuford Mills, to Shuford Yarns. As of yet, we have not received
documentation that this change has taken place. This renewal application was completed
under the name "Shuford Yarns".
If you have further question or comment, please contact me at [phone], or via
email a mhawes@a,shurtape.com.
Sincerely,
Shuford Yarns, LLC
Mark E. Hawes, PE
cc: Jerry Eplin
Khalid Maj eed
Ron Davis

NOTICE OF RENEWAL INTENT
Application for renewal of existing coverage under General Permit NCG500000
Existing Certificate of Coverage (CoQ: NCG500 321
(Please print or type)
1) bailing address* of facility owner/operator
Company Name S H U P®R-0 YAAA15, 4-1»L
Owner Name S AUPOko APWS (- AT7-/I/,_ (Y1 dkr- Ydl,-�s i
Street Address 1125- -TA r k I~tr6 l20h 5q
City H I C.✓ op- Y State jV L ZIP Code 2 6 6 0a
Telephone Number 322 3��? " �4�44. �,S ii Fax: K22 y " Z3`,
Email address M kCWC 5h�r Icy- CDM
* Address to which all permit correspondence should be mailed
2) ]Location of facility producing discharges
Facility Name S N U Fo tfAA 'q As 5)—�)UDLat
��� rp FAC, 4' T"
Facility Contact Ta2:�qsi c. AL C n d r A
Street Address 5 t Q® 63 (2P,A/5 (Z C1 A4
City C�a AA/ 17 ��-Ls State f1� L ZIP Code � 3a
County
Telephone Number !W? `` 3C{(> `i Fax:
Email address rv� �a t� cs @ v��a A� c D'-\-
3) Description of Discharges
a) Is the discharge directly to the receiving stream? 1$Yes ❑ No
(If no, submit a site map with the pathway to the potential receiving waters clearly marked. This includes tracing the pathway of the
storm sewer to the discharge point, if the storm sewer is the only viable means of discharge.)
b) Number of discharge outfalls (ditches, pipes, channels, etc. that convey wastewater from the property):
oo J-.
c) What type of wastewater is discharged? Indicate which discharge points, if more than one.
WNon-contact cooling water Outfall(s) #: dd i
❑ Boiler Blowdown Outfall (s) #:
Page 1 of 3

The following information must be included. in triplicate [original + 2 copies] with this application or it will
be returned as incomplete.
Site snap. If the discharge is not directly to a stream, the pathway to the receiving stream must
be clearly indicated. This includes tracing the pathway of a storm sewer to its discharge point.
> Authorization f°or -ZePresellltatives. If this application will be submitted by a consulting
engineer (or engineering firm), include documentation from the Permittee showing that the
consultant submitting the application has been designated an Authorized ?Representative of the
applicant.
-, �W :
�e;�� �liication
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:
Title: \' ` i\�4_; `OJ
6 Q
(Signature off
North Carolina General Statute 143-2!5.6 b (i) provi,des that:
/ 3 rY 07
(Date Signed)
Any person who knowingly makes any false statement, representation, or certification in any application, 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.)
This Notice of Renewal intent does NOT reuire a separate fee.
T7Oe 1ermitted �aciiitU already �a s an snniloa,i tee toy- coverage under NQQ5®®®®®.
Mail the original and two copies of the entire package to:
Mr. Charles H. Weaver
NC DENR / DWQ / NPDES
1617 Mail Service Center
Raleigh, North Carolina 27699-1617
Page 3of3

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MizyLb used to compiy Vv-411
OSHA's Hazard Communication Standard,
29 CFR 1910.1200. Standard must be
consulted for specific requirements.
.a d.. '. ',�:'..„ r�;°•,�T'`"%'2
Occupational Safety End Health Administration
(Non-i'viandatory Form)
Form Approved
OMB No. 1218-0072
'
IDENTITY (As Used on Label and List)
CWT-501
!dote: Blank spaces are not permitted. IP any item is not applicable, or no
information is available, the space must be marked to indicate that.
Section I
Manufacturer's Name
Elements Illustrated Inc.
Emergency Telephone Number
1-800-672-1697
Address (Number, Street, City, State, and ZIP Code)
2714 First Ave. NW
Telephone Number for Information
828-322-6421
Date Prepared -
Revised June, 2000
Hickory, NC 28601
Signature of Preparer (optional)
Section lI — Hazardous Ingredients/identity InfOrMRt On
Hazardous Components (Specific Chemical Identity; Common Name(s))
Other Limits
OSHA PEL ACGIH TLV Recommended
% (optional)
POLY OXYETHYLENE (DIMETHYLIMINO) ETHYLENEDICHLORIDE
150
Qim&ri}Inn III rharacteristics
Boiling Point
212OF
Specific Gravity (HZO = 1)
1.019
Vapor Pressure (mm Hg.)
Melting Point
N/A
@200C
17.53,
Vapor Density (AIR - 1)
Evaporation Rate
NOT
ESTABLISH)
1.0
(Butyf Acetate - 1)
Solubility in Water
,,
COMPLETE
PH
6.3
Appearance and Odor
Clear, light yellow solution with slight odor
Section IV — Fire and Explosion Hazard Data
Flash Point (Method Used) ,212O MCC) F (P Flammable Limits N/A LELN/A UELN/A
-
Extinguishing Media
For fires involving this product,water fog,cExbon dioxide & dry chemical apparatus maybe used.
Special Fire Fighting Procedures NONE
Unusual Fire and Explosion Hazards NONE
(Reproduce locally) OSHA 174, Sept. 1985

r'.c.{ IO c iG;""�/ �c a tier€ «'C G'Cf it � Labcar
�
May be used to comply with Occupational Safety and Health Administration
OSHA's Hazard Communication Standard, (Non -Mandatory Form)
29 CFR 1910.1200. Standard must be Form Approved
consulted for specific requirements. OMB No. 1218-0072
IDENTITY (As Used on Label and List) Note: Blank spaces are not permitted. If any item is not applicable, or no
CWT - 804 ' information is available, the space must be marked to indicate that.
Manufacturer's Name
Emergency Telephone Number
Elements Illustrated, Inc.
[phone]
Address (Number, Street, City, State, and ZIP Code)
Telephone Number for Information
2714 First Ave N.W.
828-322-6421
Date Prepa�w+ -
Hickory
Updated 6/2001
Signature of Preparer (optional)
North Carolina 28601
Section II — Hazardous Ingredients/Ident6ty Information
Other Limits
Hazardous Components (Specific Chemical Identity; Common Name(s)) OSHA PEL ACGIH TLV Recommended % (optional)
Trade Secret Not Established`•
SODIUM HYDROXIDE - CAS#-1310-73-2
This product contains one or more components identified as hazardous under the criteria of the OSHA
Hazard Communication Standard (29 CPR 1910,1200). The provisions of 29 CPR 1910,1200 (i)(2) will be
ied with in the event of an emergency.
Section III - Physical/Chemical Characteristics
Boiling Point
212 aF
Specific Gravity (H20 = 1)
1.15
Vapor Pressure (mm Hg.)
Not
Melting Point
N/A
Established
Vapor Density (AIR = 1)
Not
Evaporation Rate
Not
Established
(Butyl Acetate = 1) -
Established
Solubility in Water
Complete
pH
Appearance and Odor '
Clear, straw-colored liquid, slight odor
Section IV — Fire and Explosion Hazard Data
Flash Point (Method Used) Flammable Limits EL UEL
300°F (P-M CC) N/A LN/A N/A
Extinguishing Media
For fires involving this product, water may be used.
Special Fire Fighting Procedures
Wear full protective gear and self-contained breathing apparatus.
Unusual Fire and Explosion Hazards Although .this product does not meet the parameters for flammability, it can react
to some metals to form flammable hydrogen gas Irritating and/or toxic gases and aerosols may be present.
Product will burn in the presence of a strong ignition source after water is removed.
Style CU-FP174 Labelmaster, Div.of American Labelmark Co.Ine.60646 OSHA 174, Sept. 1985

i SDS NO: 0004 i
6tereal Szallet`yl zcatS Sae t
inlay be used to comply vdith
OSHA's Hazard Communication Standard,
29 CFR 1910.1200. Standard must be
consulted for specific requirements.
Deas�tment of Labor
Occupational Safety and Health Administration 4
(Non -Mandatory Form)
Form ,approved
OMB No. 1213-0072
IDENTITY (As Used on Label and List) I Note: Blank spaces are not permitfod. If any Item is not applicable, or no
AWY-25 Information is available, the space must be mer{red to indicate flint.
Section 1
Manufacturer's Name
Emergency Telephone Number
E.Zeenents_llluslr t-ed_ Ine
800-672-1697
Address (Number, Street, City, State, and ZIP Code)
Telephone Number for Information
211A P-1- A". H
[phone]
Date Prepared
Hi_ckorv. NC 28601
UPDATED 3/8/99
Signature of Preparer (optional)
Section 11 — Hazardous Ingredlenfslid, entify Information
Other Limits
Hazardous Components (Specific Chemical Identity; Common Name(s)) OSHA PEL ACGIH TLV Recommended 0/0 (npfional)
irr—la sorrmf Not Established
This product contains one or more components identified as hazardous under the criteria of the 0SIIA Hazard
Communication Standard (29 CFR 1910.1200). The provisions of 29 CFR 1910.1200 (i)(2) shall be complied
with in the event of an emergency.
Section ill — Physical/Chemical Characteristics
Boiling Point
Specific Gravity (H20 1)
210'F
1.024
Vapor Pressure (mm Hg.)
Nnt
Melling Point
_.
E- abl_i_shQd_
Not
�A
Vapor Density (AIR - 1)
Evaporation Rate
Not
Established
(Butyl Acetate = 1)
Established
—
Solubility in Water
Comp.L
9H
8.9
Appearance and Odor
Clear liquid, slight odor
Section IV — Fire and Exp.csion Hazard Data
Flash Point (Method Used) Flammable Limits LEL UEL
3007 (P - M CC) Not Established N A N A
F-06guishing Medici
For fires involving this product, water may be used.
Spkial Fire Fighting Procedures
Provide firefighters with self-contained breathing apparatus with a full -face piece operated in pressure
demand or other positive pressure mode. -
Unutual Fire and Explosion Hazards
(Reproduce locally) OSHA 174, Sept. 1985

`0'
Elements Illustrated,, ini
Industrial Water Treatment
2714 1st Avenue, NW Hickory, NC 28601 I [phone]
CA T-150 1
TRADE NAME: WSCP 60%
ACTIVE ING EDENT: Poly[oxyethylene(dimethyliminio)ethylene
(dime.thyliminio)ethylenedi chloride]
% ACTIVE: 15 %
HALE LIFE: t'A = at pH 9 = 0.50 days
LC50 DATA:
ORGANISM TEST DURATION ADJUSTED LC50 (mg/l)
Rainbow Trout 96 hr 1.88 aug/l
Bluegill Sunfish 96 hr 1.36 mg/l
Flathead Minnow 96 hr 1.72 mg/l
Daphnia. Magna 48 hr 1.48 mg/1
CWT-530
0
TRAIiE
DIME T 50 %
ACTE 1NGRE
TS: Potassium N,ITT-dimethyldithiocarbam to
min ACTIVE:
0 %
HALF LIFE:
t'./a a . 3 = 0.012 days
=1.23 days, ph 9 =1.77 day
LC50 DATA:
ORGANISM
TEST D CLN
ADJUSTED LC50 (Mg/l�
Rainbow Trout
96 hr
1.80 mg/l
Flathead Min o
96 hr
_ 0 mg/l
Daphni a
48 hr
1.70
WILL A/ T- "SO U S 67D
A7- S 1T6

11
2714 1st Avenue, NW Hickory, NC 28601 / [phone]
TRADE NAME: ACUMER 3100
ACTIVE OGRE B IER NT.- Acrylic Terpolymer
% ACTA7E- 4%
HALF LIFE: t '/; at pl-I 7 = 1. 2 days., PH 9 = 21— 2 days
LC50 DATA;
ORGANISM TEST DURATION ADJUSTED LC50 (m
Bluegill 96 hr > 1000 m gjl
Trout 96 hr > 1000 mg/l
Daphnia 48 hr > 1000 Ing/l
ANVT-25
TRADE NAME: WSCP
ACTrVEE'qGREDIENT- Poly[oxNethNetli1,riene(dime4ttiNIimiiii-oletiiyleiie
(dimethyllmlfflo)ethylene dichlorldel
lfo ACTIVE: 4%
HALF LIFE: t 1,2' = at pH 9 = 0-50 days
LC50 DATA:
ORGANISM
Ralnbaw Trout
Bluegill Sunfish
Flathead Minnow
Daphnia
TEST DURATION
96 hr
96 hr
96 hr
48 hr
ADJUSTED LC50
fll�
7.05 mg1l
5. 10 ingl
6.45 mg/l
5.55 mg/l

131OCIDE/CHEMICAL TREAT MENT
WORKSHEET-FORM 101
The following calculations are to be performed on any biocidal products ultimately discharged to the surface waters of
North Carolina. This worksheet must be completed separately for each biocidal product in use. This worksheet is to be
returned with all appropriate data entered into the designated areas with calculations performed as indicated.
I. Facility Name SHUFORD YARNS DUDLEY SHOALS FACILITY
NPDES # NC G500321 Outfall #001
County CALDWELL
Receiving Stream UPPER LITTLE RIVER 7Q10 5.7 (cfs) OBTAINED FROM USGS
(All above information supplied by the Division of Water Quality)
What is the Average Daily Discharge (A.D.D.) volume of the water handling systems to the receiving water body?
A.D.D. = 0.002175 (in M.G.D.)
Please calculate the Instream Waste Concentration (IWC in percent) of this discharge using the data entered
above.
IWC = (A.D.D.) X 100 (0.002175)X100 ® 0.059 %
(7Q 10)(0.646) + (A. D. D) (5.7)(0.646) + (0.002175)
This value (IWC) represents the waste concentration to the receiving stream during low flow conditions.
II. What is the name of the whole product chemical treatment proposed for use in the discharge identified in Part I?
CWT-501
Please list the active ingredients and percent composition:
Polyjoxkethylene(dimethyliminio)ethylene(dimethyliminio)ethylenedichloride 15% %
What feed or dosage rate (D.R.) is used in this application? The units must be converted to maximum grams
of whole product used in a 24hr period.
D.R.= 3777.3 grams/24hr period
Please note, fluid ounces (a volume) must be converted to grams (a mass). The formula for this conversion is:
Grams of product= fluid oz. of product X 1 gal. water X 8.34 lbs. X specific gravity of product X 453.590.
128 fl. oz. 1 gal. water 1 lb.

Fecillty arise: Si-FUFORla Y/-ERNS DUDLEY SHCALS 1 AQ: LITY MIRDES : NOG 500321
Estimate total volume of the water handling system between entry of biocidai product and NPDES discharge point.
On an attached sheet please provide justification for this estimate (system volume, average cycles per biowdown,
holding lagoon size, etc.)
Volume= 0.005200 million gallons
What is the pH of the handling system prior to biocide addition? If unknown, enter N/A. AVERAGE pH — 8.5
What is the decay rate (D.K.) of the product? If unknown, assume no decay (D.K.=O) and proceed to asterisk.
The degradation must be stated at pH level within 1/2 pH standard unit within handling system. Enter the half life
(Half Life is the time required for the initial product to degrade to half of its original concentration). please provide
copies of the sources of this data.
H.L. = 0.50 Days SOURCE IS SUPPLIER DATA, WHICH IS ATTACHED.
The decay rate is equal to H1L X 0.69 = 1.38 =Decay Rate (D.K.)
Calculate degradation factor (D.F.). This is the first order loss coefficient.
* D.F. = A.D.D. + (D.K.) _ (0.002175) + (1.38) = 1.80
(Volume) (0.005200)
Calculate Steady State Discharge Concentration:
3777.3 107 m /1
Dischg Conc. _ (D.F.)(Vol me)(3785) (1.8)(0 005200)(3785) g
Calculate concentration of biocide instream during low flow conditions.
(Receiving Stream Concentration)
(Dischg. Conc.) x (IWC%) _ (107)x(0.059) = 0.063 mg/I
100 100
Receiving Stream Concentration
II1: Calculate regulated limitation.
List all LC50 and EC50 data available for the whole product according to the following columns. (Note that units
should be in mg/1). Please provide copies of the sources of this data. SOURCES ATTACHED.
Organism
DAPHNIA MAGNA
RAINBOW TROUT
FATHEAD MINNOW
BLUEGILL SUNFISH
Test Duration
48-H R
96-HR
96-HR
96-H R
LC50/EC50 (mg/1)
1.48
1.88
1.72
1.36
D. W. Q. Form 101 (612000)
2

Facility Name: SHUFORD YARNS. DUDLEY SHOALS FACILITY NPDES : NCG 5 0321
Choose the lowest LC50/EC50 listed above:
Enter the LC50/EC50: 1.36 MG/L
If the half Fife (H.L.) is less than 4 days, perform the following calculation.
Regulated Limitation = 0.05 x LC50 = 0.068 mg/I
If the half life (H.L.) is greater than or equal to 4 days or unknown, perform the following calculation
Regulated Limitation = 0.01 x LC50 = mg/I
Choose the appropriate regulated limitation from the calculations immediately above and place in this blank:
0.068 mg/liter
From Part 11 enter the receiving stream concentration:
0.063 mg/liter
IV. Analysis.
If the receiving stream concentration is greater than the calculated regulated limitation, then this biocide is
unacceptable for use.
Person in Responsible Charge
,, �v A, t i i> � F'r a C
Name (Print)
C � / 3C)
Signature Date
Person Completing This Worksheet (If different from above)
Name (Print)
Signature Date
Please submit to: Division of Water Quality
Aquatic Toxicology Unit
1621 Mail Service Center
Raleigh, NC 27699-1621
Attn: Todd Christenson
D. W. Q. Form 101 (612000) 3

s e' SI-ii <:� DUD! E�� SI-[Gr',I_ r ,"ICI €`i `'til�'IF� l G 500321
acility Nam . � i=GILD .�,
Sug��lemental Metals Analy�is
if copper, zinc, or chromium are present in the proposed biocidal compound, complete this worksheet. A separate form
must be used for each metal and/or metal compound present in the biocide. List the metal, its chemical formula, molecular
weight (MW), formula weight (FW), and the concentration of the metal compound in the biocide (MCC). Complete a
separate form for every metal present in the biocide. NO METALS KNOWN OR BELIEVED TO BE PRESENT.
Metal Chemical Formula Molecular Weight of Metal Formula Weight Concentration in Biocide
EXAMPLE
Copper CuSO4®5H20 63.546 g/mole 249.680 g/mole 0.2
Dosage rate of Blocide (DR) (from page 1),
DR = grams/day
Average Daily Discharge (ADD) (from page 1),
ADD = million gallons/day
Discharge Concentration (DC) of Blocide:
DC = DR - ( grams/day) _ grams/million gallons
ADD ( million gallons/day)
Convert DC to micrograms/liter (ppb):
DC (pg) _ (g gal) 1 x 106 gag/c1 =
/I DC rams/million al x 3.785 x 106 liters/million gal. Ng/I
Calculate the fraction of metal in the metal -containing compound (F):
MW ( grams/mole)
MF = FW = ( grams/mole) _
Calculate the fraction of metal in the biocidal compound (BF):
BF=MFxMCC
000% - ( )%
x 100
Calculate the concentration of metal in the discharge ():
M = DC x BF = lag/I x = Ng/I
Calculate the instream metal concentration (IMC) at low -flow conditions:
IWC % _ % _ /I
IMC = M x 100 - u9/I x 100 N9
Regulated limitation of metal (from below): pg/I
NC General Statutes 15A NCAC 26.0211 define:
Copper- 7 gag/I water quality action level* Zinc- 50 gag/I water quality action level*
Chromium- 50 gag/I water quality standard
(*Values which exceed action levels must be addressed directly by aquatic toxicity testing.)
D. W. Q. Form 101 (612000) 4

BIOCIDE/CHEMICAL TREATMENT
WORKSHEET-FORM 101
The following calculations are to be performed on any biocidal products ultimately discharged to the surface waters of
North Carolina. This worksheet must be completed separately for each biocidal product in use. This worksheet is to be
returned with all appropriate data entered into the designated areas with calculations performed as indicated.
I. Facility Name SHUFORD YARNS, DUDLEY_SHOALS FACILITY
NPDES # NC G500321 Outfall #001
County CALDWELL
Receiving Stream UPPER LITTLE RIVER 7010 5.7 (cfs) OBTAINED FROM USGS
(All above information supplied by the Division of Water Quality)
What is the Average Daily Discharge (A.D.D.) volume of the water handling systems to the receiving water body?
A.D.D. = 0.001425 (in M.G.D.)
Please calculate the Instream Waste Concentration (IWC in percent) of this discharge using the data entered
above.
'WC = (A.D.D.) X 100 (0.001425)A'100 e 0.039 %
(7Q10)(0.646) + (A.D.D) m (5.7)(0.646) + (0.001425)
This value (IWC) represents the waste concentration to the receiving stream during low flow conditions.
II. What is the name of the whole product chemical treatment proposed for use in the discharge identified in Part I?
CWT-804
Please list the active ingredients and percent composition:
ACRYLIC TERPOLYMER 4% %
What feed or dosage rate (D.R.) is used in this application? The units must be converted to maximum grams
of whole product used in'a 24hr period.
D.R.= 2225 grams/24hr period
Please note, fluid ounces (a volume) must be converted to grams (a mass). The formula for this conversion is:
Grams of product = fluid oz. of product X 1 gal. water X 8.34 lbs. X specific gravity of product X 453.599.
128 fl. oz. 1 gal. water 1 lb.

racili y Nam a: Ste- UFORD ` ARMS . DUCLEY S3HCALS FACAI ITY 7-DES 4 C 5C032 i
Estimate total volume of the water handling system between entry of biocidal product and NPDES discharge point.
On an attached sheet please provide justification for this estimate (system volume, average cycles per blowdown,
holding lagoon size, etc.)
Volume= 0.003000 million gallons
What is the pH of the handling system prior to biocide addition? if unknown, enter N/A. AVERAGE pH — 8.5
What is the decay rate (D.K.) of the product? If unknown, assume no decay (D.K.=0) and proceed to asterisk.
The degradation must be stated at pH level within 1 /2 pH standard unit within handling system. Enter the half life
(Half Life is the time required for the initial product to degrade to half of its original concentration). Piease provide
copies of the sources of this data.
H.L. = 2.2 Days SOURCE IS SUPPLIER DATA, WHICH IS ATTACHED.
The decay rate is equal to H1L X 0.69 = 0.314 =Decay Rate (D.K.)
Calculate degradation factor (D.F.). This is the first order loss coefficient.
* D.F. = A.D.D. + D.K.) _ (0.001425) + (0.314) = 0.789
(Volume) ( (0.003000)
Calculate Steady State Discharge Concentration:
2225 248 m /I
(
Dischg Conc. = (D.F.)(Volume)(3785) _ 0.789)(0.003000)(3785) s g
Calculate concentration of biocide instream during low flow conditions.
(Receiving Stream Concentration)
(Dischg. Conc.) x (IWC%) _ (248)x(0.039) = 0.097 mg/I
100 100
Receiving Stream Concentration
Ill. Calculate regulated limitation.
List all LC50 and EC50 data available for the whole product according to the following columns. (Note that units
should be in mg/1). Please provide copies of the sources of this data. SOURCES ATTACHED.
Organism Test Duration LC50/EC50 (mg/I)
DAPHNIA
48-HR
>1000
TROUT
96-HR
>1000
BLUEGILL
96-HR
>1000
D. W. Q. Form 101 (612000) 2

Facility Name: SHUFORD YARNS DUDLEY SHOALS FACILITY NPDES #: NCG 500321
Fac ty —
Choose the lowest LC50/EC50 listed above:
Enter the LC50/EC50: 1000 MG/L
If the half life (H.L.) is less than 4 days, perform the following calculation.
Regulated Limitation = 0.05 x LC50 = 50 mg/I
If the half life (H.L.) is greater than or equal to 4 days or unknown, perform the following calculation.
Regulated Limitation = 0.01 x LC50 = mg/I
Choose the appropriate regulated limitation from the calculations immediately above and place in this blank:
50 mg/liter
From Part II enter the receiving stream concentration:
0.097 mg/liter
IV. Analysis.
If the receiving stream concentration is greater than the calculated regulated limitation, then this biocide is
unacceptable for use.
Person in Responsible Charge
Name (Print)
Qua ' -7
ig tune Date
Person Completing This Worksheet (If different from above)
�L" Cf I1 W. E'0 4 k
'—Name (Print)
(,t
Signature Date
Please submit to: Division of Water Quality
Aquatic Toxicology Unit
1621 Mail Service Center
Raleigh, NC 27699-1621
Attn: Todd Christenson
3
D. W. Q. Form 101 (612000)

Facifty IXame: Si-UFORD YARNS Dl DLEY 11HOAt S FACItUTY iNfl'IDL::S i�vC 50032'
Supplemental Metals Analysis
if copper, zinc, or chromium are present in the proposed biocidal compound, complete this worksheet. A separate form
must be used for each metal and/or metal compound present in the biocide. List the metal, its chemical formula, molecular
weight (MW), formula weight (FW), and the concentration of the metal compound in the biocide (MCC). Complete a
separate form for every metal present in the biocide. NO METALS KNOWN OR BELIEVED TO BE PRESENT
Metal Chemical Formula Molecular Weight of Metal Formula Weight Concentration in Biocide
EXAMPLE
Copper CuSO4°5H2O 63.546 g/mole 249.680 g/mole 0.2
Dosage rate of Blocide (DR) (from page 1):
DR = grams/day
Average Daily Discharge (ADD) (from page 1):
ADD = million gallons/day
Discharge Concentration (DC) of Blocide:
DR ( rams/day) _ grams/million gallons
DC = ADD = (million gallons/day)
Convert DC to micrograms/liter (ppb):
1 x 106 u9/g _
DC (lag/l) = DC (grams/million gal) x 3.785 x 106 liters/million gal. hg/I
Calculate the fraction of metal in the metal -containing compound (MF):
MW ( grams/mole) _
MF = FW = ( grams/mole) _
Calculate the fraction of metal in the blocidal compound (BF):
_
BF = MF x MCC % 100 = x %
(100)
Calculate the concentration of metal in the discharge ():
M = DC x BF = pg/I x = pg/l
Calculate the instream metal concentration (IMC) at low -flow conditions:
IWC % _ % /I
IMC = M x 100 _ ug/l x 100 EJg
Regulated limitation of metal (from below):
NC General Statutes 15A NCAC 213.0211 define:
Copper- 7 Ng/l water quality action level* Zinc- 50 Ng/l water quality action level*
Chromium- 50 pg/l water quality standard
(*Values which exceed action levels must be addressed directly by aquatic toxicity testing.)
4
D.W.Q. Form 101 (612000)

610CIDE/CHEMICAL TREATMENT
WORKSHEET-FORM 101
The following calculations are to be performed on any biocidal products ultimately discharged to the surface waters of
North Carolina. This worksheet must be completed separately for each biocidal product in use. This worksheet is to be
returned with all appropriate data entered into the designated areas with calculations performed as indicated.
I. Facility Name SHUFORD YARNS DUDLEY SHOALS FACILITY
NPDES # NC G500321 Outfall #001
County CALDWELL
Receiving Stream UPPER LITTLE RIVER 7Q10 5.7 (cfs) OBTAINED FROM USGS
(All above information supplied by the Division of Water Quality)
What is the Average Daily Discharge (A.D.D.) volume of the water handling systems to the receiving water body?
A.D.D. = 0.00075 (in M.G.D.)
Please calculate the Instream Waste Concentration (IWC in percent) of this discharge using the data entered
above.
(A.D.D.) X 100
IWC (M10)(0.646) + (A.D.D)
(0.00075)X100
(5.7)(0.646) + (0.00075)
This value (IWC) represents the waste concentration to the receiving stream during low flow conditions.
II. What is the name of the whole product chemical treatment proposed for use in the discharge identified in Part I?
AWT-25
Please list the active ingredients and percent composition:
Poly[oxytheyethylene(dimethyliminio)ethylene(dimethyliminio)ethylene dichloride 4% %
What feed or dosage rate (D.R.) is used in this application? The units must be converted to maximum grams
of whole product used in a 24hr period.
D.R.= 1776 grams/24hr period
Please note, fluid ounces (a volume) must be converted to grams (a mass). The formula for this conversion is:
Grams of product = fluid oz. of product X 1 gal. water X 8.34 lbs. X specific gravity of product X 451 .59a.
128 fl. oz. 1 gal. water

Facility !dams: Sl-iUFORD YARI�S is IiOLE`r ci Orl_S rr CiLI `° MiPCES ,.: t CC 500321
Estimate total volume of the water handling system between entry of biocidal product and NP cES discharge point.
On an attached sheet please provide justification for this estimate (system volume, average cycles per blowdown,
holding lagoon size, etc.)
Volume= 0.00075 million gallons
What is the pH of the handling system prior to biocide addition? If unknown, enter N/A. AVERAGE pH a 8.5
What is the decay rate (D.K.) of the product? If unknown, assume no decay (D.K.=O) and proceed to asterisk.
The degradation must be stated at pH level within 1 /2 pH standard unit within handling system. Enter the half life
(Half Life is the time required for the initial product to degrade to half of its original concentration). Piease provide
copies of the sources of this data.
H.L. = 0.5 Days SOURCE IS SUPPLIER DATA, WHICH IS ATTACHED.
The decay rate is equal to H1L X 0.69 = 1.38 =Decay Rate (D.K.)
Calculate degradation factor (D.F.). This is the first order loss coefficient.
D.F. = A. D. D. + (D. K.) (0.00075) + (1.38) = 1.72
(Volume) (0.002200)
Calculate Steady State Discharge Concentration:
(D.R.) (1776) — 124 mg/I
Dischg Conc. = (D.F.)(Volume)(3785) — (1.72)(0.002200)(3785) e
Calculate concentration of biocide instream during low flow conditions.
(Receiving Stream Concentration)
(Dischg. Conc.) x (IWC%o) _ (124x(0.020) = 0.025 mg/I
100 100
Receiving Stream Concentration
III. Calculate regulated limitation.
List all LC50 and EC50 data available for the whole product according to the following columns. (Note that units
should be in mg/1). Please provide copies of the sources of this data. SOURCES ATTACHED.
Organism Test Duration
DAPHNIA 48-HR
RAINBOW TROUT 96-HR
BLUEGILL SUNFISH 96-HR
FLATHEAD MINNOW 96-HR
LC50/EC50 (mg/1)
5.55
7.05
5.10
6.45
D. W. Q. Form 101 (612000) 2

Facility Name: SHUFORD YARNS, DUDLEY SHOALS FACILITY NPDES #: NCa!j00321
Choose the lowest LC50/EC50 listed above:
Enter the LC50/EC50: 5.1 -MG1L
If the half life (H.L.) is less than 4 days, perform the following calculation.
Regulated Limitation = 0.05 x LC50 = 0.255 mg/I
If the half life (H.L.) is greater than or equal to 4 days or unknown, perform the following calculation.
Regulated Limitation = 0.01 x LC50 = mg/I
Choose the appropriate regulated limitation from the calculations immediately above and place in this blank:
0.255 mg/liter
From Part 11 enter the receiving stream concentration:
0.025 mg/liter
Analysis.
If the receiving stream concentration is greater than the calculated regulated limitation, then this biocide is
unacceptable for use.
Person in Responsible Charge
Pt L
Name (Print)
kwj 1- 30 - 6
I Zignature Date
Person Completing This Worksheet (if different from above)
o
I Name (Print)
&O/L 1- 30- 2-00-j'
A.-
V Signature Date
Please submit to: Division of Water Quality
Aquatic Toxicology Unit
1621 Mail Service Center
Raleigh, NC 27699-1621
Attn: Todd Christenson
D. W. Q. Form 101 (612000) 3

=G:cil drr i�Fan e: Si-iI FCF.1 `! �i , Di -)LEY SHC,f�i_ f �',C'iLiTY i, iPDH;�: =+[CG 5t00321
Subolernental Metals Analysis
If copper, zinc, or chromium are present in the proposed biocidal compound, complete this worksheet. A separate form
must be used for each metal and/or metal compound present in the biocide. List the metal, its chemical formula, molecular
weight (MW), formula weight (FW), and the concentration of the metal compound in the biocide (MCC). Complete a
separate form for every metal present in the biocide. NO METALS KNOWN OR BELIEVED TO BE PRESENT
Metal Chemical Formula Molecular Weight of Metal Formula Weight Concentration in Biocide
EXAMPLE
Copper CuSO4a5H20 63.546 g/mole 249.680 g/mole 0.2
Dosage rate of fBlocide (DR) (from page 1):
DR = grams/day
Average Daily Discharge (ADD) (from page 1):
ADD = million gallons/day
Discharge Concentration (DC) of Blocide:
DC = DR - ( grams/day) _ grams/million gallons
ADD - (_million gallons/day)
Convert DC to micrograms/liter (ppb):
DC (lag/1) _ DC (grams/million gal) x 1 x 106 hg/g6 = Ia9/I
3.785 x 10 liters/million gal.
Calculate the fraction of metal in the metal -containing compound (MF):
MW ( grams/mole)
MF = FW = ( grams/mole) _
Calculate the fraction of metal in the biocidal compound (IMF):
BF=MFxMCC %o = x % _
100 (100)
Calculate the concentration of metal in the discharge ():
M = DC x BF = lag/I x = lag/I
Calculate the instreasn metal concentration (IMC) at low -flow conditions:
IMC = M x IWC % = hg/I x % = lag/I
100 100
Regulated
NC General Statutes 15A NCAC 26.0211 define:
Copper 7 pg/l water quality action level* Zinc- 50 pg/I water quality action level*
Chromium- 50 pg/1 water quality standard
("Values which exceed action levels must be addressed directly by aquatic toxicity testing.)
D. W. Q. Form 101 (612000) 4

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11 February 2009
Mr. Roger Edwards
Surface Water Protection Supervisor
Division of Water Quality
North Carolina Department of Environment
and Natural Resources
2090 U.S. Highway 70
Swannanoa, North Carolina 28778
hufa:
Yams3
hh� k
p FEB 13 2009
w� ; Y �-G (T ON
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Subject: Dechlorination Unit Installation & Certification of No Discharge
NPDES Permit No. NCG500321
Dudley Shoals Plant
Caldwell County
Dear Mr. Edwards:
Shuford Yarns' Dudley Shoals facility was issued the subject General Permit which limited the
effluent concentration of total residual chlorine (TRC). Therefore, to meet the required effluent
concentration, the facility has designed, received approval and completed installation of a tablet type
dechlorination system. The permit specified the TRC effluent limitation for existing discharges would
become effective 18 months after the effective date of the permit. The effective date of the permit was 1
August 2007. We discovered on 9 February 2009 that we had incorrectly interpreted the compliance date
as 18 February 2009 instead of 1 February 2009. Thus, our Environmental Director, Mark Hawes,
contacted you via telephone on 10 February 2009 to verbally report the error and provide a summary of
actions to assure compliance with the effluent limitation for TRC.
Construction of the dechlorination system began on 16 January 2009. Since 16 January 2009,
Shuford Yarns can confirm that the cooling towers, air wash systems, and boiler (out of service for more
than 5 years) have not discharged. During the winter months the cooling towers are taken out of service
and the air wash system run on a limited basis with pump floats adjusted to prevent water levels from
reaching levels that would discharge. During the construction process these pieces of equipment have been
disconnected from the drain lines. Therefore, Shuford Yarns is certifying that the systems have not
discharge since 16 January 2009 and, more specifically, have not discharged after the time the TRC
effluent limitation went into effect on 1 February 2009.
On 10 February 2009, construction was completed on the dechlorination system. Today the
design engineer will be evaluating the finished construction to verify the system is ready for operation. We
expect to provide the 48 hour notification later today or tomorrow to commence operation of the new
system as soon as the need arises to bring the cooling systems back on line.
We regret this error, but point out that compliance has been maintained by the cooling systems not
discharging. If you have any questions, please contact Mark Hawes at 828.325.5428 or myself at
828.324.7430. ,.----
Respectfully,
'rY a.
Khalid Majeed
Vice President of Manufacturing
1985 Tate Blvd SE, Box 54, Hickory, NC 28602
Corporate Phone: [phone] Corporate Fax: [phone]

NCDENR
North Carolina Department of Environment and Natural Resources
Division of Water Quality
Michael F. Easley, Governor
Mark E. Hawes
Shuford Mills, Inc.
P.O. Box 2228
Hickory, NC
Dear Permittee:
28603-2228
William G. Ross, Jr., Secretary
Alan W. Klimek, P.E., Director
November 15, 2006
Subject: NPDES Permit NCG500000 renewal
Certificate of Coverage (CoC) NCG500321
Shuford Mills Inc -Dudley Shoal
Caldwell County
The facility listed above is covered under NPDES General Permit NCG500000. NCG500000 expires
on July 31, 2007. Federal (40 CFR 122.41) and North Carolina (15A NCAC 2H.0105(e)) regulations require
that permit renewal applications must be filed at least 180 days prior to expiration of the current permit. If
you have already mailed a renewal request, you may disregard this notice.
To satisfy this requirement, the Division must receive a renewal request postmarked no later than
February 1, 2007. Failure to request renewal by this date may result in a civil penalty assessment. Larger
penalties may be assessed depending upon the delinquency of the request. This renewal notice is being sent
well in advance of the due date so that you have adequate time to prepare your application.
If any discharge previously covered under NCG500000 will occur after July 31, 2007, the
CoC must be renewed. Discharge of wastewater without a valid permit would violate North Carolina
General Statute 143-215.1; unpermitted discharges of wastewater may be assessed civil penalties of up to
$25,000 per day.
If all discharge has ceased at your facility and you wish to rescind this CoC [or if you have other
questions], contact me at the telephone number or e-mail address listed below.
Sincerely,
Charles H. Weaver, Jr.
NPDES Unit
cc: Central Files
NPDES File
1617 Mail Service Center, Raleigh, North Carolina 27699-1617
512 North Salisbury Street, Raleigh, North Carolina 27604
Phone: [phone], extension 511 / FAX [phone] / charles.weaver@ ncmai1.net
1�df' r ' JAL i " 0 One
An Equal Opportunity/Affirmative Action Employer— 50% Recycled/10% Post Consumer Paper

�OF W A%9Q Michael F. Easley, Governor
William G. Ross Jr., Secretary
CO r North Carolina Department of Environment and Natural Resources
O `C Alan W. Klimek, P.E. Director
Division of Water Quality
August ;16, 2006
Allen Barwick
Shuford Yarns, LLC
1985 Tate Blvd. S.E., Bog 54
Hickory, NC 28602
Subject NPDES Permit Modification
Permit NCG500321
Shuford Yarns LLC - Dudley Shoal
formerly Shuford Mills Inc.
Caldwell County
Dear Mr. Barwick
Division personnel have reviewed and approved your change of address request of the subject permit, received on
June 27, 2006. This permit modification documents the change in ownership. -
Please find enclosed the revised permit including a copy of the Certificate of Coverage, copy of the General
Wastewater Discharge Permit NCG500000, and a copy of a Technical Bulletin for General Wastewater Discharge
Permit NCG500000. All other terms and conditions contained in the original permit remain unchanged and in full
effect. This permit modification is issued under the requirements of North Carolina General Statutes 143-215.1 and
the Memorandum of Agreement between North Carolina and the U.S. Environmental Protection Agency.
If you have any questions concerning this permit modification, please contact the Point Source Branch at (919)
733-5083 extension 363 or 350.
Sincerely,
�nW. limek, P.E.
cc: Central Files
Asheville Regional Office, Surface Water Protection
NPDES Unit File
y
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VV I [ C J
nc
N°aiurulla
North Carolina Division of Water Quality 1617 Mail Service Center Raleigh, NC 27699-1617 Phone [phone] Customer Service
Internet h2o.enr state.naus 512 N. Salisbury St. Raleigh, NC 27604 FAX [phone]
An Equal Opportunity/Affirmative Action Employer— 50% Recycled/10% Post Consumer Paper

STATE OF NORTH CAROLINA
DEPARTMENT OF ENVIRONMENT AND NATURAL RESOURCES
DIVISION OF WATER QUALITY
GENERAL PERMIT NO. NCG500000
CERTIFICATE OF COVERAGE No. NCG500321
TO DISCHARGE NON -CONTACT COOLING WATER, COOLING TOWER AND BOILER BLOWDOWN,
CONDENSATE AND SIMILAR WASTEWATERS 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;
SHUFORD YARNS, LLC
is hereby authorized to discharge
COOLING TOWER BLOWDOWN
water or similar wastewater from a facility located at
SHURFORD YARNS, LLC — DUDLEY SHOAL
NCSR 1749 BURNS ROAD
DUDLEY SHOALS
CALDWELL COUNTY
to receiving waters designated as the Upper Little River, a class WS-IV water, in the Catawba River Basin in
accordance with the effluent limitations, monitoring requirements, and other conditions set forth in Parts I,11,111, and
IV of General Permit No. NCG500000 as attached.
This certificate of coverage shall become effective August 16, 2006.
This Certificate of Coverage shall remain in effect for the duration of the General Permit.
Signed this day August 16, 2006.
04­4AIan W. Klimek, P.E., Director
Division of Water Quality
By Authority of the Environmental Management Commission

State of North Carolina
Department of Environment
and Natural Resources
Division of Water Quality
Michael F. Easley, Governor
William G. Ross Jr., Secretary
Alan W. Klimek, P.E., Director
MARK HAWES
SHUFORD MILLS INC-DUDLEY SHOAL
PO BOX 2228
HICKORY, NC 28601
Dear Permittee:
1•�
NCDENR
NORTH CAROLINA DEPARTMENT OF
ENVIRONMENT AND NATURAL RESOURCES
July 26, 2002
Subject: Reissue - NPDES Wastewater Discharge Permit
Shuford Mills Inc -Dudley Shoal
COC Number NCG500321
Caldwell County
In response to your renewal application for continued coverage under general permit NCG500000, the Division of
Water Quality (DWQ) is forwarding herewith the reissued wastewater general permit Certificate of Coverage
(COC). This COC is reissued pursuant to the requirements of North Carolina General Statute 143-215.1 and the
Memorandum of Agreement between the state of North Carolina and the U.S. Environmental Protection Agency,
dated May 9, 1994 (or as subsquently amended).
The following information is included with your permit package:
* A copy of the Certificate of Coverage for your treatment facility
* A copy of General Wastewater Discharge Permit NCG500000
* A copy of a Technical Bulletin for General Wastewater Discharge Permit NCG500000
Your coverage under this general permit is not transferable except after notice to DWQ. The Division may require
modification or revocation and reissuance of the Certificate of Coverage. This permit does not affect the legal
requirements to obtain other permits which may be required by DENR or relieve the permittee from responsibility
for compliance with any other applicable federal, state, or local law rule, standard, ordinance, order, judgment, or
decree.
If you have any questions regarding this permit package please contact Aisha Lau of the Central Office Stormwater
and General Permits Unit at [phone], ext. 578
Sincerely,
for Alan W. Klimek, P.E.
cc: Central Files
Stormwater & General Permits Unit Files
Asheville Regional Office
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

State of North Carolina
Department of Environment
and Natural Resources
Division of Water Quality
Michael F. Easley, Governor
William G. Ross Jr., Secretary
Gregory J. Thorpe, Ph.D., Acting Director
THOMAS Z GUTHRIE
SHUFORD MILLS INC-DUDLEY SHOAL
PO BOX 2228
HICKORY, NC 28601
Dear Permittee:
11/26/2001
Subject: NPDES Wastewater Permit Coverage Renewal
Shuford Mills Inc-dudley Shoal
COC Number NCG500321
Caldwell County
Your facility is currently covered for wastewater discharge under General Permit NCG500000. This permit expires
on July 31, 2002. Division of Water Quality (DWQ) staff is in the process of rewriting this permit with a
scheduled reissue in the summer of 2002. Once the permit is reissued, your facility would be eligible for continued
coverage under the reissued permit.
In order to assure your continued coverage under the general permit, you must apply to the DWQ for renewal of
your permit coverage. To make this renewal process easier, we are informing you in advance that your permit
coverage will be expiring. Enclosed you will find a general permit coverage renewal application form. This
will serve as your application for renewal of your permit coverage. The application must be completed and
returned with the required information by February 01, 2002 in order to assure continued coverage under the
general permit. There is no renewal fee associated with this process. Your facility will be invoiced for the annual
permit fee at a later date.
Failure to request renewal within this time period may result in a civil assessment of at least $250.00. Larger
penalties may be assessed depending on the delinquency of the request. Discharge of wastewater from your facility
without coverage under a valid wastewater NPDES permit would constitute a violation of NCGS 143-215.1 and
could result in assessments of civil penalties of up to $10,000 per day.
If the subject wastewater discharge to waters of the state has been terminated, please complete the enclosed
rescission request form. Mailing instructions are listed on the bottom of the form. You will be notified when the
rescission process has been completed.
If you have any questions regarding the permit coverage renewal procedures please contact the Asheville Regional
Office at 828-251-6208 or Delonda Alexander of the Central Office Stormwater Unit at [phone], ext. 584
cc: Central Files
Stormwater and General Permits Unit Files
Asheville Regional Office
Sincerely,
Bradley Bennett, Supervisor
Stormwater and General Permits Unit
1617 Mail Service Center, Raleigh, North Carolina 27699-1617
An Equal Opportunity Affirmative Action Employer
Telephone [phone] FAX [phone]
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