NC0000108_Permit (Modification)_20040607 (2)

NPDES DOCYNBUT SCANNING COVER SHEET
NPDES Permit: NC0000108
Document Type: Permit Issuance
Wasteload Allocation
Authorization to Construct (AtC)
Permit Modification
Complete File - Historical
Monitoring Report •
Instream Assessment (67B)
Environmental Assessment (EA)
Permit
History
Document Date: June 7, 2004
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A
` �GF V11 TF9Q Michael F.Easley
A Governor
O r NCDEN DEN R William G.Ross,Jr.,Secretary
North Carolina Department of Environment and Natural Resources
Alan W. Klimek,P.E.,Director
Division of Water Quality
dune-7_2004
Mr. Mike Bell
Director of Environmental;Engineering
Coats North America
P.O. Box 670 i'lCrZ 441til.,,i 3 f9p3r
Toccoa, Georgia 30577
Subject: Modification of NPDES Permit NC0000108
Sylvan Plant WWTP
Transylvania County
Dear Mr. Bell:
The subject individual NPDES permit issued on April 20, 2001 has been modified as per your
request. Please find attached the modified sections of this permit, and replace the old pages with the
modified pages. This permit modification 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 (and as subsequently amended). The
modifications become effective immediately.
The following permit modification is authorized by this letter:
• The limitations and monitoring requirements for Outfalls 001 and 002 were suspended. The
facility has shut down manufacturing operations at the Sylvan Plant and no longer discharges
non-contact cooling waters.
• Outfall 003 has been retained with modifications. A daily maximum limit of 28 lag/L for Total
Residual Chlorine was included in the permit. A TRC policy was adopted by the Division in
April 2003. Facilities that didn't have TRC limits will get limits at renewal or re-issuance of
the permit. A compliance schedule of 18 months was added to the permit. Also, a daily
maximum limit of 35 mg/f was added for ammonia. The Division has been adding daily
maximum limits for ammonia to permits with monthly averages since December 2002 in order
to conform to Federal NPDES regulations.
• A special condition was added to the permit including requirements to be fulfilled in the event
that the facility resumes manufacturing or changes ownership.
Please find enclosed the revised pages, which should be inserted into your permit. The old pages
may then be discarded. 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 any parts, measurement frequencies or sampling requirements contained in this permit
modification 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 a written petition
conforming to Chapter 150B of the North Carolina General Statutes, filed with the Office of
Administrative Hearings (6714 Mail Service Center, Raleigh, North Carolina 27699-6714). Unless such
demand is made, this decision shall be final and binding,
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 may be required.
1617 Mail Service Center,Raleigh,North Carolina 27699-1617 Telephone[phone]$3 FAX[phone]
An Equal Opportunity Affirmative Action Employer VISIT us ON THE INTERNET 0 http://h2o.enr.state.ne.us/NPDES

Mr. Mike Sell
NPDES Permit No. NC{1000108
If you have any questions concerning this permit modification, please contact Teresa Rodriguez of
the NPDES Unit at [phone], extension 553.
Sincerely,
ORIGINAL SIGNED BY
Michael E. Templeton
Alan W. Klimek, P.E.
cc: Central Files
Asheville Regional Office, Water Quality Section
NPDES U7

Permit NC0000108
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,
Coats American, Inc.
is hereby authorized to discharge wastewater from a facility located at the
Sylvan Plant
Old US Hwy 64 East
Northeast of Rosman
Transylvania County
to receiving waters designated as Galloway Creek in the French 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 July 1, 2004.
This permit and authorization to discharge shall expire at midnight on September 30, 2005.
Signed this day June 7, 2004.
10R4G{NAL TlG p e pBY
Mlchae4 E.
Alan W. Klimek, P.E., Director
Division of Water Quality
By Authority of the Environmental Management Commission

Permit NC0000108
SUPPLEMENT TO PERMIT COVER SHEET
Coats American, Incorporated is hereby authorized to:
1. Continue to operate an existing 0.015 MGD extended aeration package wastewater
treatment system with effluent disinfection to discharge at outfall 003, located at
Sylvan Plant, on Old US Highway 64 East, Transylvania County, and
2. Discharge from said treatment works at the location specified on the attached map
into Galloway Creek which is classified C waters in the French Broad River Basin.

Permit NCO000108 '
A. (IL.) EFFLUENT LIMITATIONS AND MONITORING REQUIREMENTS — FINAL
During the period beginning on the effective date of this permit and lasting until permit expiration, the
authorization to discharge from outfall 001 is suspended until this permit is modified pursuant to
Condition A. (4).
A. (2.) EFFLUENT LIMITATIONS AND MONITORING REQUIREMENTS — FINAL
During the period beginning on the effective date of this permit and lasting until permit expiration, the
authorization to discharge from outfaU 002 is suspended until this permit is modified pursuant to
Condition A. (4).
A. (3.) EFFLUENT LIMITATIONS AND MONITORING REQUIREMENTS — FINAL
During the period beginning on the effective date of this permit and lasting until permit expiration, the
Permittee is authorized to discharge from outfall 003: domestic wastewater. Such discharges shall be
limited and monitored by the Permittee as specified below:
EFFLUENT' LIMITS MONfTORING REQUIREMENTS
CHARACTERISTICS
t ;
3
Monthly ally Measurement` =16rnple:Type Sample Location
Avera g a Maximum Fre dent
Flow 0.015 MGD Weekly Instantaneous Influent or Effluent
60Ds,20oC 30.0 m /L 45.0 m L Weekly Grab Effluent
Total Suspended Residue 30.0 m 45.0 m L Weekly Grab Effluent
NH3 as N, 21.0 m 35.0 mgA Weekly Grab Effluent
Fecal Coliform(geometric mean 200/100 mL 4001100 mL Weekly Grab Effluent
Total Residual Chlorine2 28 L 2Meek Grab Effluent
[Temperature,oC Weekly Grab Effluent
Footnotes:
1. From November 1 through March 31, NH3-N shall not have a limit.
2. The TRC. limit shall take effect on January 1, 2006. Until then, the permittee shall monitor TRC
(with no limit).
The pH shall not be less than 6.0 standard units nor greater than 9.0 standard units and shall be
monitored 2/month at the effluent by grab sample.
There shall be no discharge of floating solids or visible foam in other than trace amounts.
A. (4.) CHANGE IN OWNERSHIP OR USE OF THE FACILITY
Prior to resuming operations at the Sylvan Plant or in the event that the facility changes ownership, the
Permittee shall submit a request for permit modification including the following documentation at least
180 days prior to the start of operations:
1. Description of manufacturing processes, products, and expected annual production.
2. Flow diagram indicating process and wastewater flow volumes.
3. Proposed treatment and characteristics of the wastewater to be discharged.
4. Description of any planned expansions or upgrades to the manufacturing or treatment facilities.
5. Engineering Alternatives Analysis of wastewater disposal alternatives including the connection to an
existing municipal waste treatment facility and non-discharge alternatives.
6. If the facility is sold a name ownership change form and required documentation shall be submitted
to the Division.
No additional discharge is authorized until the effective date of the permit modification.

Re: Ccfats North America- NC0000108
Subject: Re: Coats North America - NC0000108
From: Kerry Becker <[e-mail]>
Date: Mon;-29_Mar 2004=14:51:28 -0500
To: Teresa Rodriguez <[e-mail]>
Teresa:
I couldn' t remember if I had replied to this already or not so here
goes .
Coats America is closed down. Outfalls 001 and 002 refer to their
cooling
towers/stormwater. Outfall 003 is the main wastewater treatment
plant for
the bathrooms . They are trying to find a buyer for the plant and
wish to
keep the permit for the 003 Outfall availahle for a new industry.
There is
an outside chance that the plant could reopen. . . . . . . .but it is a
very very
slim outside chance. Kerry
Teresa Rodriguez wrote:
Kerry,
I have a request from Coats North America to eliminate Outfalls
001 and
002 from their permit . They want to keep Outfall 003 . I would
like your
preliminary comments on this, do you know if the plant shut down
completely and why would they need to keep the permit for the
WWTP?
Thanks,
Teresa
Teresa Rodriguez, P.E.
Division of Water Quality
NPDES Unit
919-733-5083
Kerry Becker - Kerry.Becker@ncmail .net
North Carolina Dept . of Environment and Natural Resources
Asheville Regional Office
Division of Water Quality - Water Quality Section
59 Woodfin Place
Asheville, NC 28801
Tel : [phone]
Fax: [phone]
1 of 2 4/8/2004 7:40 AM

Coats North America
Coats PO Box 670
6212 Rase Lane
• North America Phone: G( 30577
Phone: (7D6)886-2141
Fax: [phone]
[january=21,-2064 }
Mr. David Goodrich i � "_�. _.�'' ��
: j
NC Department of Water Quality/ NPDES Unit j
1617 Mail Service Center �l JAN 29 2004
Raleigh,NC 27699-1617
Reference: Aquatic Toxicity Testing fln �fvP�r���' ';'Y
i
q `7 g c�r'�i�,r
Coats American-Transylvania County �`y
Permit No. NCO000108
Dear Mr, Goodrich:
Coats North America requests modification of the above plant's NPDES permit or other
administrative means to discontinue monitoring and reporting requirements, including aquatic
toxicity testing,for Outfalls 001 and 002. Manufacturing operations ceased at this plant on
September 30, 2003,with removal of most of the production equipment by December 31, 2003.
Referring to the attached Schematic of Wastewater Flow, dated February 24, 2000,all of the
process wastewater sources have been shutdown and drained. Thus,the potential to contribute
pollutants to the wastewater from these sources has been eliminated.
However, Coats needs to retain it NPDES permit for continuing intermittent discharge of
sanitary wastes through Outfall 003 that is processed by a package wastewater treatment
system.
Please call, fax or E-mail (mike.bell®coats.com)any questions or comments you may have about
this request.
Sincerely,
COATS NORTH AMERICA
1 ' ) l 1` � .
Mike Bell
Director of Environmental Engineering
Attachment
cc: (Via Facsimile-2 pages)
Mr. Keith Haynes- Asheville Regional Office
Ms. Kerry Becker- Asheville Regional Office
Mr. Wesley Royal-Royal Water Works,Inc.
Mr. Don Deemer-ERM-SE
Mr. Tom Kitchen