NC0020737_Permit (Issuance)_20040331

NPDES DOCUMENT SCANNIN& COVER SHEET
NPDES Permit: NC0020737
Kings Mountain WWTP
Document Type: Permit Issua ce
Wasteload Allocation
Authorization to Construct (AtC)
Permit Modification
Correspondence
201 Facilities Plan
Instream Assessment (67B)
Environmental Assessment (EA)
Permit
History
Document Date: March 31, 2004
TiaiB documeat is pria:ted oa rewse paper aay
ooateatt oa tIILe reire m e iaide

O�O� WATF,QpG Michael F.Easley,Governor
State of North Carolina
William G. Ross,Jr.,Secretary
r Department of Environment and Natural Resources
7 Alan W.Klimek,P.E., Director
O Division of Water Quality
March 31, 2004
Mr. Kenneth Downey
City of Kings Mountain
P.O. Box 429 Ji,r
Kings Mountain, North Carol is �280861i;(yj'
Subject: NPDES Permit Issuance
Permit NCO020737
Pilot Creek WWTP
Cleveland County
Dear Mr. Downey:
Division personnel have reviewed and approved your application for renewal of the
subject permit. Accordingly, we are forwarding the attached final NPDES discharge permit.
This permit is issued pursuant to the requirements of North Carolina General Statute 143-
215.1 and the Memorandum of Agreement between North Carolina and the U.S.
Environmental Protection Agency dated May 9, 1994 (or as subsequently amended).
The attached final permit contains several revisions from the draft in response to
comments received by US EPA. Twice per month monitoring has been included for total
chromium, total cyanide, and total nickel based on their presence in the effluent.
Furthermore, the 70% total suspended solids removal efficiency is good only for the term of
this permit. Extension of the 85% waiver must be requested upon renewal.
Compliance with all terms and conditions of the attached permit is the responsibility
of the Permittee. Please note that T15A 08G .0204 of the North Carolina Administrative Code
has been interpreted to mean that the Operator in Responsible Charge is responsible for
operation of water pollution control systems.
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 permit shall be final
and binding.
Please take notice that this permit is not transferable. 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, Coastal Area Management Act,
or any other Federal or Local governmental permits which may be required.
1617 MAIL SERVICE CENTER, RALEIGH, NORTH CAROLINA 27699-1 61 7- TELEPHONE [phone]/FAX [phone]
VISIT US ON THE WEB AT http:/fh2o.enr.state.nc.us/NPDES

Permit No. NCO020737
Town of Kings Mountain
Page 2
If you have any questions or need additional information, please do not hesitate to
contact Mark McIntire of my staff at [phone], extension 508.
Sincerely,
ORIGINAL SIGNED BY
Mark McIntire
Alan W. Klimek, P.E.
cc: Central Files
{NPDES-Unit-Files
Mooresville Regional Office
Aquatic Toxicology Unit
US EPA Region IV

Permit NCO020737
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,
City of Kings Mountain
is hereby authorized to discharge wastewater from a facility located at the
Pilot Creek WWTP
Off U.S. Highway 74 Bypass
West of Kings Mountain
Cleveland County
to receiving waters designated as Buffalo Creek in the Broad River Basin
in accordance with effluent limitations, monitoring requirements, and other conditions
set forth in Parts I, II, III and IV hereof.
This permit shall become effective May 1, 2004.
This permit and authorization to discharge shall expire at midnight on August 31, 2008.
Signed this day March 31, 2004.
8JI}UIoIM �JeW
)k9 a3N`JIS ldN1�JRI0 '
Alan W. Klimek, P.E.
Division of Water Quality
By Authority of the Environmental Management Commission

Permit NC0020737
SUPPLEMENT TO PERMIT COVER SHEET
All previous NPDES Permits issued to this facility, whether for operation or discharge, are hereby
revoked. [The exclusive authority to operate this facility arises under this permit. The authority to
operate the facility under previously issued permits bearing this number is no longer effective.] The
conditions, requirements, terms and provisions of this permit authorizing discharge under the NPDES
govern discharges from this facility.
The City of Kings Mountain is hereby authorized to:
1. Continue to operate al 6.0 MGD wastewater treatment plant- consisting of dua7"117l)
WEW
screw pumps, a bar screen, Parshall flume with recorder, low diversion, four (4)
aeration basins, four (4) secondary clarifiers,3 chlorine contact basins,
''dechlorination facilities, aerobic digesters and a belt press located at the Pilot
Creek WWTP, off U.S. Highway 74 Bypass, west of Kings Mountain in Cleveland
County.
2. Discharge from said treatment works at the location specified on the attached
map into Buffalo Creek, which is classified C waters in the Broad River Basin.
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Pilot Creek NC0026737' Facility ':
ocati dn
USGS Quad
ELM35,15!35" !V
Namie:-Mado .,
Receiving Stream:I-Buffalo'Creek-. �102.'T26"
Stream"Cl'ass: C:.
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Subbasin: Broad-030805 orthNbt to SCALE.

Permit NCO020737
A. (1.) EFFLUENT LIMITATIONS AND MONITORING REQUIREMENTS
During the period beginning on the effective date of this permit and lasting until expiration, the Permittee is
authorized to discharge from outfall 001. Such discharges shall be limited and monitored by the Permittee as
specified below:
;EFFLUENT ._ �'; c+ LIMITS , 51 MONITORING REQUIREMENTS ,
r
,CHARACTERISTICS:
Monthly Weekly:" Daily Measurement Sample Type `Sample:Locaiwnr
. :rAverage . ..Avers a , Maximum. . Frequency i
Flow 6.0 MGD Daily Instantaneous Influent or Effluent
BODs,20TC(April 1-October 31 2 28.0 mg/L 42.0 mg/L Daily Composite Effluent, Influent
BODs,20TC(November 1-March 30.0 mg/L 45.0 mg/L Daily Composite Effluent, Influent
31)2
Total Suspended Solids3 30.0 mg/L 45.0 mg/L Daily Composite I Effluent, Influent
NH3 as N(April 1 -October 31 2.6 mg/L 7.8 mg/L Daily Composite Effluent
NH3 as N November 1-March 31 8.9 mg/L 26.7 m Daily Composite Effluent
Dissolved Oxygen4 Daily Grab Effluent
Fecal Coliform 200/100 ml 4001100 ml Daily Grab Effluent
(geometric mean
Total Residual Chlorine 28 µg/L Daily Grab Effluent
H Between 6.0-9.0 Standard Units Daily Grab Effluent
TemperatureIT) Daily Grab Effluent
Total Nitrogen NO2+NO3+TKN Quarterly Composite Effluent
Total Phosphorus Quarterly Composite Effluent
Chronic Toxicity,5 Quarterly Composite Effluent
Total Cadmium 6.1 µg/L 15 µg/L Weekly Composite Effluent
Chloride 2/Month Composite Effluent
Total Copper 2/Month Composite Effluent
Total Zinc 2/1VIonth Composite Effluent
Total Chromium 2/Month Composite Effluent
Total Cyanide 2/1VIonth Grab Effluent
Total Nickel 2/Month Composite Effluent
Dissolved Oxygen6 6 Grab Upstream,
Downstream
Temperature(^C)6 6 Grab Upstream,
Downstream
PrioritV Pollutant Scan See condition A. 3 of this permit
ConductiviV 6 Grab Upstream,
Downstream
Notes:
1. Sample locations: Upstream - Upstream 100 yards above outfall; Downstream - Downstream at NCSR
1103.
2. The monthly average effluent BOD5 concentration shall not exceed 15% of the respective influent
value (85% removal).
3. The monthly average effluent Total Suspended Solids concentration shall not exceed 30% of the
respective influent value (70% removal). This waiver from the 85% removal requirement applies only
for the term of the permit. Continuation of this waiver must be requested upon renewal.
4. The daily average dissolved oxygen concentration shall not be less than 5. 0 mg/L.
5. Whole Effluent Toxicity shall be measured by the Chronic Toxicity (P/F) test using Ceriodaphnia dubia
at 33%. Testing shall be conducted in January, April, July and October (see Part A. (2.)). Toxicant
sampling shall coincide with toxicity testing.
6. Instream samples shall be collected three times per week during the months of June-September and
once per week during the remaining months of the year.
There shall be no discharge of floating solids or visible foam in other than trace amounts.

Permit NCO020737
A. (2.) CHRONIC TOXICITY 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 33%.
The permit holder shall perform at a minimum, quarterlu 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
January, April, July and October. 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 11 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 11 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 whieff tests were performed, using the parameter
code TGP313 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: North Carolina Division of Water Quality
Environmental Sciences Branch
1621 Mail Service Center
Raleigh, North Carolina 27699-1621
Completed Aquatic Toxicity Test Forms shall be filed with the Environmental Sciences Branch no later
than 30 days after the end of the reporting period for which the report is made.
Test data shall be complete, accurate, include all supporting chemical/physical measurements
and all concentration/response data, and be certified by laboratory supervisor and ORC or approved
designate signature. Total residual chlorine of the effluent toxicity sample must be measured and
reported if chlorine is employed for disinfection of the waste stream.
Should there be no discharge of flow from the facility during a month in which toxicity monitoring
is required, the Permittee will complete the information located at the top of the aquatic toxicity (AT) test
form indicating the facility name, permit number, pipe number, county, and the month/year of the report
with the notation of "No Flow" in the comment area of the form. The report shall be submitted to the
Environmental Sciences Branch at the address cited above.
Should the Permittee fail to monitor during a month in which toxicity monitoring is required,
monitoring will be required during the following month.
Should any test data from this monitoring requirement or tests performed by the North Carolina
Division of Water Quality indicate potential impacts to the receiving stream, this permit may be re-opened
and modified to include alternate monitoring requirements or limits.
NOTE: Failure to achieve test conditions as specified in the cited document, such as minimum control
organism survival, minimum control organism reproduction, and appropriate environmental controls,
shall constitute an invalid test and will require immediate follow-up testing to be completed no later than
the last day of the month following the month of the initial monitoring.

Permit NCO020737
A. (3.) EFFLUENT POLLUTANT SCAN
The Permittee shall perform an annual Effluent Pollutant Scan for all parameters listed in the attached table (in
accordance with 40 CFR Part 136). Samples shall represent seasonal variations. Unless otherwise indicated,
metals shall be analyzed as "total recoverable."
Ammonia(as N) Trans-1,2-dichloroethylene Bis(2-chloroethyl)ether
Chlorine(total residual,THC) 1,1-dichloroethylene Bis(2-chloroisopropyl)ether
Dissolved oxygen 1,2-dichloropropane Bis(2-ethylhexyl)phthalate
NitmtelNitme 1,3-dichloropropylene 4-bromophenyl phenyl ether
Kjeldahl nitrogen Ethylbenzene Butyl benzyl phthalate
Oil and grease Methyl bromide 2-chloronaphthalene
Phosphorus Methyl chloride 4-chlorophenyl phenyl ether
Total dissolved solids Methylene chloride Chrysene
Hardness 1,1,2,2-tetrachloroethane Di-n-butyl phthalate
Antimony Tetrachloroethylene Di-n-octyl phthalate
Arsenic Toluene Dibenzo(a,h)anthracene
Beryllium 1,1,1-tdchbroethane 1,2-dichlorobenzene
Cadmium 1,1,2-trichloroethane 1,3-dichlorobenzene
Chromium Trichloroethylene 1,4-dichlorobenzene
Copper Vinyl chloride 3,3dichlorobenzidine
Lead Acid-extractable compounds: Diethyl phthalate
Mercury P.-chloro-m-creso Dimethyl phthalate
Nickel 2-chlorophenol 2,4-dinitrotoluene
Selenium 2,4-dichlorophenol 2,6-dinitrotoluene
Silver 2,4-dimethylphenol 1,2-diphenylhydrazine
Thallium 4,6-dinitro-o-cresol Fluoranthene
Zinc - 2,4-dinNophenol Fluorene
Cyanide 2-nitrophenol Hexachlorobenzene
Total phenolic compounds 4-nitrophenol Hexachlorobutadiene
Volatile organic compounds Pentachlorophenol Hexachlorocyclo-pentadiene
Acrolein Phenol Hexachloroethane
Acrylonitrile 2,4,6-tdchlorophenol Indeno(1,2,3-cd)pyren9
Benzene Base-neutral compounds: Isophorone
Bromoform Acenaphthene Naphthalene
Carbon tetrachloride Acenaphthylene Nitrobenzene .
Chlorobenzene - Anthracene N-nitrosodi-n-propylamine
Chlorodibromomethane Benzidine N-nitrosodimethylamine
Chloroethane Benzo(a)anthracene N-nitrosodiphenylemine
2-chloroethylvinyl ether Benzo(a)pyrene Phenanthrene
Chloroform 3,4 benzofluoranthene Pyrene
Dichlorobromomethane Benzo(ghi)per lene 1,2,4-tdchlorobenzene
1,1-dichloroethane Benzo(k)fluoranthene
1,2-dichbroethane Bis(2chloroethoxy)methane
Test results shall be reported to the Division in DWQ Form-A MR-PPAI or in a form approved by
the Director within 90 days of sampling. The report shall be submitted to the following address:
Division of Water Quality, Water Quality Section, Central Files, 1617 Mail Service Center, Raleigh,
North Carolina 27699-1617.

9 CoNaeo0the°`d penaii'
*d othei<supporbngpinroe
mahon on fileusedrtode
terming conddions.present..
'in;+then draft permit are
THE STAR jayail t request ,
payment ant off thhe-cos ts of re:
tpretluetion. Mail€comments'
;and/or.requests for,'infor-
mation to the NC,Division
February 11, 2004 of Water Quality.at the
.above address or call Ms.
NCDENR/DWQ/ NPDES Valary.Stephers.,at (819) I
PUBLIC N0710E 733.5083, extension 520.
1617 MAIL SERVICE CENTER Please Indicate"the NPDES I
RALEIGH NC 27699-1617 STATE OF a perms numEer(attached)in
NORTN.CAROLINA.•. - any conimunicatloh.-,Imer-
ATTN: VALERY STEPHENS ENvieofilmtNTA'L :- acted persons may also
MANAGIEMgNT - ' visit the'Division'of Water
.4 COMMISSIOW; duakty at 512 N. Salisbury.;'
NPDES UNIT- .;Street,, . Raleigh, '.NC r
1617 MAIL SERVICE - "276040148 between the
PUBLIC NOTICE CENTER;RALEIGH,NC;- hours Of 8:00 a.m:and 5:00
NOTIFICATION OF INTENT TO ISSUE A NPDES WAS 27SWI6178rr- p.m. to review information
•.,..'Y/l",:.„5 .on file.
NOTIRCATION OF-q
IM'ENTTo�ISSUE,, 9r -".CNA Holdings, Inc.has ap-
A NP,OES WASTEWATER 'plied for renewal- of its
PERMIT ` " yk_ ,NPDES permit for the
! i a i Tlcona Facility
CLEVELAND COUNTY on the basis of a thorough (NC0004652) in Shelby,
start review and applicatbn :NC, dlevoland -County,
I, Tina McCombs, Classified Advertising of NC General Statute 'discharging a mardmum of
9 newspaper news a er
Manager at THE STAR, a 143.21,-Publio;Iaw 92-500 .�0.8MGD'of.treated domes-
and other lawful standards tic - Sand industrial'
published in Shelby, N. C., do and reguladons, the North wastewater to:: Buffalo
.Carolina Environmental ;.,creek a class.-C•wst r"in
solemnly swear that the advertisement Management Commission the,Broatl Rider Basin`-No
hereto annexed appeared in the PrOPOses to issue a Natlon 6immeters are wstar quaA-.
at Pollutant Discharge ty,limded ho/dever this dis-
SHELBY STAR , for one Elimination - System .charge may Impact future
successive s week/da beginning HODES)iwastewater Oils. allocation of this aquattc're.
y g charge"permit to the per ;souma t
(� FEB. 08 ��,(((]]]((Q]]Q�Q son(s)-llstedsbelow`e8ec - ) a n I
/� Uve 45 daft from the putr tTha crTy of IWgs'Moun sin
l.J� fish date'ol this nobce:i' ` tias'elplied for renewal the•
�1 hi • NPDES perms tor;rls' -
CIaSSifie Advertising Manager Written comments regard. Creeks ,,,-(„u.;,Wyy7 Pilatp
Ing the proposed penny will ?y(NC0020737).=TKe f-if
be accepted undl 301 days y`ispermmed to discharge up.
after the.publish date ptthlu 'yto"8.01MGD of treated tlo- '
Swom to and subscribed before me no ce f'AOicrommeme'o m c wastewater;i_nto But-
cebed'prior to that data are i feb Creak,to 9-bless "C i
on this the 11TH day of FEBRUARY, 2004 (?on,
as ad,m the hn dada st tam in the B oad River
termmationa regaidingithe Basin 'Currently"ammo-
gyp- rpropoa,a rpermh The'D1 ehia nhrogen'and cadmium"
IYWAA ly.�(�-JiC.(,.-1-J1 (r a:m�the NC Diwskin of (ere�wetere quality limited."
- Water iQuafiry may tl'i de �Thla'dsZhirge may unpam
t. otary Public ro hdd:a"pudb mesting'for future allocabon o1 the is-.I
�E ED(y he proposed penny should source r3 t_,
)P q� tthe DMiionvrewiva(aiel4 l"'$'�,�'
]rdfiaant degrulof public;in The City
of Shelby"has aP.
p O(ARY N y0ir r^ terest� g t t r priad,fof renews of NPDES
Q c+ ®� MY COMMISSION E,: 1• __ P"fi for its waatawater
j11t/• y treatment*�. ' taciiity
PVB��G 2 --- �(N00024538) This facility
Is ipermitted to discharge a
maximum of 6.0 MGD of
1 treated "domestic
NDC wastewater to-the"First.
- i" Broad River,a class C wat-
er in the Broad River Basin.
Currently . ammo-
FEB 1 3 2004 nia-nitrogen; cyanide, and
nickel are water quality lim.
ited. This discharge may
Impact future allocation-of"
this resource. .
February6,2004ltc'• "'

Re:re City of Kings Mountain
Subject: Re: re City of Kings Mountain
From: [e-mail]
Date: Mon, 22 Mar 2004 1 1:17:06 -0500
To: Mark McIntire <[e-mail]>
yes, issue when ready.
I of] 3/22/2004 1 1:24 AM

Re:comments on NC0020737,City of Kings Mountain
Subject: Re:comments on NC0020737,City of Kings Mountain
From: Mark McIntire<[e-mail]>
Date: Wed, 10 Mar 2004 09:48:55 -0500
To: [e-mail]
Ok, this one was one of Natalie's that I sent to notice for her, so I've had to do quite a bit of
research to figure out what's going on here. I'll just go down the list:
1. The facility gave me data over the phone fox nitrate+nitrite and 06G. Their nitrate+nitrite maximum
is roughly 14.4 mg/L, their average is roughly 6.8 mg/L. For oil a grease, their max. is around 90
mg/L, their average is a little less than 30 mg/L. Can I note those values in the application with my
initials?
2. I reran the RPA for chromium using all reported data for 2002 and 2003. The maximum predicted
concentration was 53.5 ppb with an allowable concentration of 152.2 ppb. The maxi. value reported in
the application appears to have been an historical value not representative of current conditions. As
such, I don't think it's reasonable to limit chromium, however, it should have been included as a
monitory only paxamter on a 2/month basis. Cyanide is not monitored in the effluent. The maximum value
reported on the application does not correspond with any data submitted in conjunction with the
facility's LTMP. That being said, I propose to install 2/month cyanide monitoring.
3. I reran the RPA for nickel using all reported data for 2002 and 2003. The maximum predicted
concentration was 254 ppb with an allowable concentration of 268 ppb. As such, a limit isn't warranted.
As for nickel's connection to toxicity and the TIE that was performed, it appears that the tox.
problems were occuring in 2000 and 2001. The facility, in association with the TIE, evidently
implemented a successful strategy to control nickel. I intend to change the monthly monitoring
requirement to 2/month for consistency with other non-limited parameters.
4. 1 took a look at Kings Mountain's influent TSS data for 2003. The average influent TSS
concentration for that period was 109 mg/L. This is roughly what their historical influent TSS values
have been. In light of the "textbook" values for influent TSS (roughly 250 mg/L), it seems reasonable
to maintain the 70% removal requirement for TSS given they need to remove, on average, 72% to comply
with their monthly average limitation of 30 mg/L.
5. PH will be changed to pH before issuance of the permit.
Do you need a fact sheet amendment for this one explaining the above rationales?
Thanks,
Mark
[e-mail] wrote:
don't think I've heard back from you on this. Can you get back to me
tomorrow? If not, I'll have to request an extension since I'm likely
out thurs and fri and our deadline is fri.
----- Forwarded by Marshall Hyatt/R4/USEPA/US on 03/09/2004 04:23 PM
Marshall
Hyatt
To:
[e-mail] 02/20/2004 01:40
cc: Madolyn Dominy/R4/USEPA/US@EPA,
PM [e-mail]
Subject: comments on NC0020737, City of Kings
Mountain
hope these are useful. will you be able to respond by March 3? thanks
Marshall
1. Table B.6 of the permit application is blank for the parameters
nitrate+nitrite and for oil and grease. Can the facility provide any
data for these at this time, since the application should have contained
at least one sample for each?
2. Based on 2_ samples, the permit application reports a daily max' value
of 0.165 mg/1 for chromium and 0.021 mg/l for cyanide. NC's NQ criteria
are 50 ug/1 (total recoverable) and 5.0 ug/l, respectively. It appears
I of 3/10/20049:51 AM

Re:comMents on NC0020737,City of Kings Mountain
there is reasonable potential based on these values to exceed NC
criteria, but the permit does not contain limits or monitoring. Pls
explain.
3. The fact sheet indicates that a TIE was done and that nickel was the
source of the toxicity. The fact sheet does say there is no RP for
nickel, but that doesn't make sense if the TIE says nickel is the source
of toxicity. Pis explain.
4. The draft permit contains a 70% removal minimum for TSS. This
appears to be a carryover from the existing permit. At each permit
renewal, justification/documentation for renewing this limit that is
consistent with 40 CFR Part 133.103 must be provided. The fact sheet
does not contain such a rationale. w/o such a rationale and a revised
fact sheet, EPA would have to object. Do you have such documentation
that you can provide? If not, we may have to go with an interim
objection until that documentation is provided.
5. PH should be pH.
2 of 3/10/2004 9:51 NM

DENR/DWQ
FACT SHEET FOR NPDES PERMIT DEVELOPMENT
NPDES No. NCO020737
Facility Information
Applicant/Facility Name: City of Kings Mountain/Pilot Creek WWTP
Applicant Address: P.O. Box 429; Kings Mountain, North Carolina 28086
Facility Address: Off US Route 74; Kings Mountain, North Carolina 28086
Permitted Flow 6.0 MGD
Type of Waste: Domestic (10%) and industrial (90%) with pretreatment program
Facility/Permit Status: Class IV/Active; Renewal
Count Cleveland Count
Miscellaneous
Receiving Stream: Buffalo Creek Regional Office: Mooresville (MRO)
Stream Classification: C State Grid/-USGS Quad: F13SW
303(d) Listed? No Permit Writer: Natalie V. Sierra
Subbasin: 03-08-05 Date: September 16, 2003
Drainage Area(mi2): 116
Summer 10((cfs) 19 �� — ---
Winter 7Q10(cfs) 42
30Q2 (cfs) N/A e
Average Flow (cfs): 162
IWC (%): 33%
Lat. 35° I5' 35"N Long. R I°2T 36"W
BACKGROUND
The Pilot Creek WWTP is a Class IV facility with a permitted flow of 6.0 MGD. The plant treats
wastewater from residential, commercial and industrial sources. The permit was originally
issued on January 22, 1999 and expired on August 31, 2003. The Permittee submitted EPA
Form 2A on February 26, 2003 in order to request renewal of the permit.
Prior to renewal, the City lost a major industry, Anvil, and this has severely reduced the flow
through the plant. Excess flow, which was previously sent to the City of Gastonia's Crowders
Creek WWTP, will now be treated at the Pilot Creek facility. The City has a full pretreatment
Long Term Monitoring Plan (LTMP) which will continue to be implemented in the coming
permit term.
The facility has experienced a number of compliance problems in the last permit term, primarily
for toxicity failures.
Instream Monitoring, Verification of Existing Conditions and DMR Data Review
This facility discharges to Buffalo Creek in subbasin 043-08-05 of the Broad River Basin.
Buffalo Creek is classified C waters at the point of discharge and is not on the 2002-303(d) list.
Kings Mountain is required to sample upstream and downstream of the discharge for dissolved
oxygen, temperature, fecal coliform, and conductivity. Plots of these data, which were culled
from Discharge Monitoring Reports (DMRs) dating from January 2001-July 2003, are attached
to this fact sheet. Little difference was noted between upstream and downstream values for
dissolved oxygen, temperature, and fecal coliform. Moreover, all of the instream values for
dissolved oxygen were above the stream standard of 5.0 mg/L and the majority of the fecal
coliform values were below 200 cfu/100 mL. There was a noticeable difference between the
upstream and downstream conductivity values.
Effluent DMR data from January 2001 through May 2003 were reviewed. Data for conventional
parameters are summarized in Table 1. For the most part, the Permittee maintained compliance
with the permit limits for those parameters.
Fact Sheet
NPDES NC00?0737 Renewal.
Purse I

f
Flow Temperature Dissolved :OD TSS Fecal
Coliforin
II
Average 2.71 1 18.65 7.74 3.72 17.67 14.13
Maximum 3.29 26.8 9.35 9.09 24.09 10.42
Minimum 2.09 10.31 6.84 2.28 11.05 1.11
Table 1. NC0020737 Conventional Data(January 2001-May 2003)
This facility also collects data for total nitrogen, total phosphorus, ammonia nitrogen
(NH -N), total residual chlorine, and chlorides. These are summarized in Table 2.
Total1 'en Total ChloridesIResidual
Phosphorus Chlorine
Average 0.08 12.4 3.29 602 15.1
Maximum 1.33 25.3 4.6 784 21.7
Minimum 0 6 2.2 350 7.95
Table 2. NC0020737 Nutrient and Toxicant Data(January 2001-May 2003)
A review of the metals (from both the DMRs and Pretreatment data) data was also performed.
These are discussed in the Reasonable Potential Analysis section.
Correspondence
The Mooresville Regional Office (MRO) conducted several site visits during this permit term to
evaluate compliance. Notices of Violation (NOVs) were issued in conjunction with some of
these inspections for permit limit violations. In all, twenty-one NOVs have been issued to the
City of Kings Mountain since March 1999. Twenty of these were issued at least in part due to a
toxicity violation or late submittal of toxicity results. One was for late submittal of the annual
fees. Miscellaneous violations of lead, cadmium and TSS limits were associated with two .
NOVs.
As a result of the consistent toxicity failures, Kings Mountain fell under the first phase of the
action level policy in 2000. A Toxicity Identification Evaluation was submitted to the MRO.
The Permittee concluded that nickel was the cause of the effluent toxicity based on tests
employing EDTA for chelation. The City was then planning on pursuing source reduction, in
part by working with its SIUs.
PERMITTING STRATEGY
Waste Load Allocation (WLA)
The Division prepared the last WLA for the previous permit renewal. The previous and current
effluent limits were based on guidelines and water quality standards. The Division has judged
previous parameters and limits to be appropriate for renewal with some exceptions. Changes to
toxicant monitoring are discussed in the Reasonable Potential Analysis section, with the
exception of ammonia.
The previous permit contains a summer limit for ammonia that appears to be based on the results
of Level B model. When assessing ammonia with respect to instream toxicity, however, it is
evident that both summer and winter limits are necessary. Based on the Instream Waste
Concentration (IWC), a summer monthly average limit of 2.6 mg/L and a winter monthly
average limit of 8.9 mg/L should be implemented. Moreover, weekly average ammonia limits
based on a 3:1 ratio with the monthly average (but no higher than 35.0 mg/L) will be
implemented in this permit. This is a new statewide policy that resulted from EPA requirements.
The resulting summer weekly average limit will be 7.8 mg/L and the winter limit will be 26.7
mg/L.
173 t sheet
NPDES NC0020737 Renewal
Page 2

In addition, an annual pollutant scan will be added such that the Permittee can collect the
necessary data required by EPA Form 2A throughout the permit term. This condition is now
standard on all major municipal permits in North Carolina.
Reasonable Potential Analysis (RPA)
The Division conducted EPA-recommended analyses to determine the reasonable potential for
toxicants to be discharged by this facility, based on DMR data from January 2000-May 2003.
Calculations included parameters listed in the previous permit and pre-treatment documents to
include: arsenic, cadmium, chloride, chromium, cyanide, fluoride, lead, mercury, nickel,
selenium, silver, copper, and zinc.
Results suggest no reasonable potential for the facility to discharge arsenic, chromium, cyanide,
fluoride, lead, mercury, nickel, silver, and selenium. Monitoring for chromium, cyanide, lead,
mercury, and fluoride, currently performed through the NPDES permit, may be eliminated from
the permit, as they are required parameters to be monitored through the Pretreatment Long Term
Monitoring Plan (LTMP). Nickel monitoring will be maintained, but reduced to monthly, due to
its association with toxicity problems.
Effluent from the facility did demonstrate reasonable potential to exceed water quality criteria for
cadmium, zinc and copper. All limits and monitoring associated with these parameters in the
current permit will be carried over into this permit term. A daily maximum limit for cadmium of
15 µg/L will be added to the permit.
SUMMARY OF PROPOSED CHANGES
In keeping with Division policies, the following will be incorporated into the permit:
New monthly and weekly average ammonia limits (both summer and winter)
Annual pollutant scan
• Elimination of the chromium, cyanide, fluoride, lead, and mercury monitoring requirements
(Permittee will continue to monitor these parameters through the LTMP).
Addition of daily maximum limit for cadmium
• Reduction of nickel monitoring to monthly
New Weekly Average and Daily Maximum limits are derived from the latest NC/EPA policies
considering '/2 FA Vs and allowable concentrations based on reasonable potential.
PROPOSED SCHEDULE FOR PERMIT ISSUANCE
Draft Permit to Public Notice: February 4, 2004
Permit Scheduled to Issue: March 29, 2004
NPDES DIVISION CONTACT
If you have questions regarding any of the above information or on the attached permit, please contact
Mark McIntire at [phone] ext. 508.
NAME: DATE:
t=9Cf Sh'Lt
NPDES NC0020737 Renawnl
Paee 3

THE CITY OF KINGS MOUNTAIN
P.O.BOX 429 • KINGS MOUNTAIN,NORTH CAROLINA 28086 • 704-734-0333
02-26-03
NCDENR/DWQ
Attn: NPDES Unit
1617 Mail Service Center
Raleigh, NC 27699-1617
Enclosed is the request for renewal for NPDES Permit#NC 0020737. Pilot Creek W WTP, Kings
Mountain. NC.
A word of explanation concerning Page 18 of 22. The numbers 3 is as presently operated.There is
considerable change in store here,as Anvil is in the process of moving their operation to the Asheville area.
This will cut into our volume and our finances in a major way. This move is.as noted, in process but date
of completion seems to be a moving target.
Once this move is completed,Ave will probably pump all flows which are now sent to Gastonia's Crowders
Creek Plant to our own Pilot Creek Plant. This decision should be finalized with the 2003/2004 budget,
which we are working on now. This will result in the numbers being 4.
Also. I was uncertain as to whose signature was needed so have asked the Mayor to sign. We hope this is
correct.
We have tried to complete all portions of these forms,but as usual, we are likely to have missed something.
If you need additional information, feel free to call Mr. Downey at the plant. 704-739-7131.
Walter C. 011is
uJ
Water Resource Director
Kings Mountain- NC
1!- MAR - 4 2003
The Historical City

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