NC0000108_Permit (Issuance)_20010420

NPDES DOCUNENT SCANNINS COVER SNEET
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: Aril 20, 2001
Tlx"dac%xxnant i�printed on rcu paper-igaorc any
C�axzteat oa the re�n►erise amide

l ,
State of North Carolina .
Department of Environment .ys �,. .... �
and Natural Resources:.
a
Division?Water dd6lity'� h
Mlcnael F.`Easley;Governor =k
Wiliam G. Ross, Jr.-, Secretary : r CDE R
Kerr T. Stevens, Director NORTH CAROLINA DEPARTMENT OF
ENVIRONMENT AND NATURAL RESOURCES
Apri1"20,.2001
Mr. Eddie Briscoe
Coats American, Sylvan Plant
P.O. Box 458
Rosman, North Carolina 28772
Subject: Issuance of NPDES Permit NC0000108
Coats American, Inc.
Transylvania County
Dear Mr. Briscoe:
Division personnel have reviewed and approved your application for renewal of the subject permit.
Accordingly, we are forwarding the attached NPDES discharge permit. This permit is issued pursuant to the
requirements of North Carolina General Statute 143-215.1 and the Memorandum of Agreement between
North Carolina and the U.S. Environmental Protection Agency dated May 9, 1994 (or as subsequently
amended).
I would like to take this opportunity to again remind you that failure to rehabilitate the chlorine
contact chamber at your facility will result in a total residual chlorine limit in your next permit.
If any parts, measurement frequencies or sampling requirements contained in this permit are
unacceptable to you, you have the right to an adjudicatory hearing upon written request within thirty (30)
days following receipt of this letter. This request must be in the form of a written petition, conforming to
Chapter 150B of the North Carolina General Statutes, and filed with the Office of Administrative Hearings
(6714 Mail Service Center, Raleigh, North Carolina 27699-6714). Unless such demand is made, this decision
shall be final and binding.
Please note that this permit is not transferable except after notice to the Division. The Division may
require modification or revocation and reissuance of the permit. This permit does not affect the le&al
requirements to obtain other permits which may be required by the Division of Water Quality or permits
required by the Division of Land Resources, the Coastal Area Management Act or any other Federal or Local
governmental permit that may be required.
If you have any questions concerning this permit, please contact Natalie Sierra at telephone number
[phone], extension 551.
Sincerely,
ORIGINAL slaNED By
BILL REID
Kerr T. Stevens
cc: Central Files
Asheville Regional Office/Water Quality Section
INPDE_ SUnitS
Point Source Compliance Enforcement Unit
Aquatic Toxicology Unit
1617 Mail Service Center,Raleigh,North Carolina 27699-1617 Telephone[phone] FAX[phone]
An Equal Opportunity Affirmative Action Employer VISIT U5 ON THE INTERNET @ http:/1h2o.enr.state.nc.us/NPDES

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, 11, III and IV hereof.
This permit shall become effective May 1, 2001.
This permit and authorization to discharge shall expire at midnight on September 30, 2005.
Signed this day April 20, 2001.
ORIGINAL SIGNM BY
BILL ROD
Kerr T. Stevens, 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, and
continue to discharge non-contact cooling water and stormwater at outfalls 001
and 002, 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.

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NC0000108 - Discharge
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NC0000108 - Coats American Facility .
Latitude: 3510'00" Sub-Basin: 04-03-01 Location ''' ° '` .'
Longitude: 82'48'30-
NC Quad R: G7NE/Rosman,
Stream Class: C Coats American.Inc.
Receiving Stream: Galloway Creek 17- NC0000108
Permitted Flow: 0.015 MODD r t Sylvan Plant

W Permit NC0000108
A. (1.). EFFLUENT LIMITATIONS AND.MONITORING�REQUIREMENTS — FINAL
71
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:
'EF�TL'UENT LIMITS MONITORING''REQUIREMENTS " �
;CHARACTERlSTICS,',� ' 1. �
�,
+� fd t,, s.Monthlyailyi� ' •Measu�emeiit Sample Type ��, Sample,t.ocation gr.
,,�#'F u` `T F.p�" � T4}3!'k?�.Y ^ ".
..dt9MR
Avers e� 8,2D
aximum lFre
Flow Semi-Annually Estimate Effluent
-+ Tem erature,�C Semi-Annually Grab Effluent
Total Residual Chlorine' Semi-Annually Grab Effluent
a Acute Toxicit z J j Quarterly Grab Effluent
Footnotes: l /
1. The temperature of the effluent shall be such as not to cause an increase of the receiving stream of more than a
2.80C increase above the natural water temperature and not to exceed a maximum of 29()C.
2. Acute Toxi�iitDty (Daphnia pulex or Ceriodaphnia) Quarterly, February, May, August and November. See A. (5.).
There shall be no discharge of floating solids or visible foam in other than trace
amounts.
There shall be no chromium, zinc or copper added to the treatment system except as a
pre-approved additive to.biocidal compounds (See A.16.).
1
The pH shall not be less than 6.0 standard units nor greater than 9.0 standard units.
1

Ly tN Permit NC00001.08
.1.._
..A: (2.)•'EFFLUENT LIMITATIONS'AND`MONITORING REQUIREMENTS'— FINAL
During the period beginning on the effective date'of this permit and lasting-until expiration, the Permittee is
authorized to discharge from outfELU 002: A/C condensate. Such discharges shall be limited and monitored by the
Permittee as specified below: '
'?'r'"tUmITS>» 'MONITORING REQUIREMt=N75,�4 �r�-2
yq I U I R c r y sS it' ! ^{
CMARACT�RISTICS �� ;, 3Ai� "u1`I �q�YR i ' �i �
, i� �g ia�, ti-...r e
Mdnthl , 'DailWa
TWleasu�emenE;. 5ariinle�T e i` Sample Locations} °
^' `Y r t -�4 rr , °°a fAvers e ,;kMaxim �U re (lent ° r
Flow Semi-Annually Estimate Effluent
Temperature,OCI Semi-Annually Grab Effluent
Total Residual Chlorine Semi-Annually Grab Effluent
Acute ToXiCity2 Quarterly Grab Effluent
Footnotes:
1. The temperature of the effluent shall be such as not to cause an increase of the receiving stream of more than a
2.8cC increase above the natural water temperature and not to exceed a maximum of 290C.
2. Acute Toxicity (Daphnia pulex or Ceriodaphnia) Quarterly, February, May, August and November. See A. (5.).
There shall be no discharge of floating solids or visible foam in other than trace
amounts.
There shall be no chromium, zinc or copper added to the treatment system except as a
pre-approved additive to biocidal compounds (See A. (6.).
The pH shall not be less than 6.0 standard units nor greater than 9.0 standard units.

Permit NC0000108
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 M � ,. LIMITS�s ` ,' �"c sr *;, MONITORINGR>=QUIR�MSNS ;' ' � ;u
GHAI�ACTERISTICS
Monthly� � Dailyp Measurementp Sample�Type .rt :Sample Location�yu ,,,,�°
d� ,,, �, ,;.T�?"�,w I�+ d� L;�" ��Stl,, � �.+
-e Maxtmum; _,.Fre uenc r
Flow 0.015 MGD Weekly Instantaneous Influent or Effluent
BOD5, 20DC 30.0 m IL 45,0 m IL Weekly Grab Effluent
Total Suspended Residue 30.0 m IL 45.0 m IL Weekly Grab Effluent
NH3 as N1 21.0 m IL Weekly Grab Effluent
Fecal Coliform(geometric mean 200/100 mL 400/100 mL Weekly Grab Effluent
Total Residual Chlorine 21Week Grab Effluent
Temperature,-C Weekly Grab Effluent
Footnotes:
1. From November 1 through March 31, NH3-N shall not have a 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.) ACUTE TOXICITY PASS/FAIL PERMIT LIMIT (QRTRLY)
The permittee shall conduct acute toxicity tests on a cruarte basis using protocols defined in
the North Carolina Procedure Document entitled "Pass/Fail Methodology For Determining
Acute Toxicity In A Single Effluent Concentration" (Revised-July, 1992 or subsequent
versions). The monitoring shall be performed as a Daphnia pulex or Ceriodaphnia dubia 24
hour static test. The effluent concentration at which there may be at no time significant acute
mortality is 90% (defined as treatment two in the procedure document). Effluent samples for
self-monitoring purposes must be obtained during representative effluent discharge below all
waste treatment. The tests will be performed during the months of February, May, August and
November.
All toxicity testing results required as part of this permit condition will be entered on the
Effluent Discharge Monitoring Form (MR-1) for the month in which it was performed, using
the parameter code TGE313 for Daphnia pulex or TGE3B for Ceriodaphnia dubia. Additionally,
DWQ Form AT-2 (original) is to be sent to the following address:
Attention:Division of Water Quality -
Environmental Sciences Branch
1621 Mail Service Center
Raleigh, N.C. 27699-1621
Test data shall be complete and accurate and include all supporting chemical/physical
measurements performed-in association with the toxicity tests, as well as all dose/response
data. Total residual chlorine of the effluent toxicity sample must be measured and reported if
chlorine is employed for disinfection of the waste stream.

Permit NC0000108 ;
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 any single quarterly monitoring indicate a failure to meet specified limits, then
monthly monitoring will begin immediately until such time that a single test is passed. Upon
passing, this monthly test requirement will revert to quarterly in the months specified above.
Should the permittee fail to monitor during a month in which toxicity monitoring is required,
then monthly monitoring will begin immediately until such time that a single test is passed.
Upon passing, this monthly test requirement will revert to quarterly in the months specified
above. �-
Should any test data from either these monitoring requirements 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 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.
A.(S.) BIOCIDE CONDITION
The permittee shall not use any biocides except those approved in conjunction with the
permit application. The permittee shall notify the Director in writing not later than ninety (90)
days prior to instituting use of any additional biocide used in cooling systems which may be
toxic to aquatic life other than those previously reported to the Division of Water Quality.
Such notification shall include completion of Biocide Worksheet Form 101 and a map locating
the discharge point and receiving stream.
A. (b.) OPTIMIZATION AND REHABILIATION CONDITION
No later than 180 days after the issuance date of this permit, the Permittee shall submit to
the Division a management plan for the chlorine contact chamber. The plan shall include, at
a minimum, the following elements:
• Assessment of existing equipment. Describe deficiencies and operational
difficulties in the existing collection system or treatment facility which affect
performance or permit compliance, and identify potential improvements to
correct those. -
• Optimization plan. Develop a strategy for optimization, rehabilitation,
expansion and/or replacement of the disinfection system to achieve optimum
performance. Identify specific measures and key tasks, including those in
the above assessment, and provide an estimated schedule for completion of
each.

AFFIDAVIT OF PUBLICAT!01�
BUNCOMBE COUNTY
SS.
NORTH CAROLINA t
Before the undersigned, a Notary Public of said
County and State, duly commissioned, qualified and
�.,
"iva srAr TICE' 5 authorized by law to administer oaths, personally
N:h sNri caRfl�r
MgNaO+ NTar, r appeared Janis Pierce, who, being first duly sworn,
Ho 5U deposes and says: that lie,(sHe) is the Legal Billing
, �bi71Vt41fWS�R ,
RYICE Clerk of TheAsheville Citizen-Times Company,
Rar aria ;NC
NOT Flea IV,
Or=!iNT AT1.ERP 2 I- engaged in publication of a newspaper known as
awas��'�'a'"+'U°s ", The Asheville Citizen=7i 'es ulilished issued
r and entered as secondlcyass rriai'l;iri`th'e City of
zrev +�Ofithar h
�"tranZot Kc`"'d'a r Asheville, in said Couiity'.'arid'Sfate- that she is
tatt,teg �a ,z �i
•w vs-saQ Ond'�otr,e'r authorized to make this,affidavit and sworn
regugurq,..f+jStanda rdsW
Caralinal',,.!�e or statement; that the notice or other legal
ntal '-"- �n�rvn-{
LOfj'"'+ +�Rnai advertisement, a true copy of which is attached
rssuera'Nrat1
"+�r�char °fa PO
hereto, was
rm�n published.in The Asheville Citizen-
{waate ',�' IN
p�rm h ,the qu`�' Times on the following date:SMaich'-9 2001. And
)l ted+ Ipyy Man( j
s�!romp' bub that the said newspaper'in which said notice, paper,
Wr document or legal Advertisement.were published
9ardi : ,°a nts rw
u t7i �wirtr , p were, at the time of each,and every publication, a
t+�e., :
is'no newspaper meeting all of the requirements and
`tO f anew � qualifications of Section 1-597of'the General
Statues of North Carolina
`an was a qualified
oI-j " newspaper within the meaning of Section 1-597 of
�b�;�, alit '
I' j the General Statues of North Carolina.
S If* Ap ,
,of
' 61''ti
`otiit,e,drart This 14th day of March, 204i 'Sent
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PCtYmquevava
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NAall (�p- rrn (SignaturToand
making allldavit)J(x;atc �fi�a6o"B Sworn subscribed before me the 14th day of
es +„�.+t�e� �� March, 2001. • ' �
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i ae�0agn °°°°art.
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° N'oNC27�ry Fo,r .auea,, Public)
k $ a 1"Tmission expires the 20th day of June, 2005.
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ti
AFFIDAVIT OF PUBLICATION
CLIPPING OF LEGAL ADVERTISING NORTH CAROLINA
ATTACHED HERE TRANSYLVANIA COUNTY
i'11131.1C.' NOTIC'fi Before the undersigned, a Notary Public of said
STATI?O NOIr '1'I I
CAIMUNA County and State, duty commissioned, qualified, and
I'Nv11t0NMI-•NTA1, authorized by law to administer oaths, personally
MANAGI'.MENT appeared David Phillips who being first duty sworn,
(:0MM1SSl0N/NPUIiS tJNI'!'
1617 MAIL Sliltvl('I? deposes and says: that he (she) is Advertising
CENTER Manager (Owner, partner, publisher, or other officer
ItAl.lil.`I1' N.C.27699-1G17 'Nc Tll�l('A•1T)N OF INTENT or employee authorized to make this affidavit) of
TO ISSUE'A.NPl)HS The Transylvania Times, published, issued, and
WAtiTFWATIAJ 111;1lMl'I' entered as second class mail in the Town of Brevard
On the basis of thorough in said County and State; that he (she) is authorized
staff review and application of
to make this affidavit and sworn statement; that the
N.C. General Statute 143.21,
Public law 92-500 and other notice or other legal advertisement, a true copy of
lawful standards and
regulations, the North Carolina which is attached hereto, was published in The
on
Environmental Management Transylvania Times on the following dates:
Commission proposes to issue a March 12, 2001
National, Pollutant Discharge
Elimination System (NPDES)
wastewater discharge permit to
the person(s) listed below
effective 45. days from the and that the said newspaper in which such notice,
publish date of this notice. paper, document, or legal advertisement was
Written comments regarding
the'•proposed permit will be published was, at the time of each, and every such
accepted until 30 days after the publication, a newspaper meeting all of the
publish date of this notice..'All
comments received prior.to that requirements and qualifications of Section I-597 of
date,are considered in the final the General Statutes of North Carolina and was
determinations 'regarding the qualified newspaper within the meaning of Section
Proposed permit. The Director
of the N.C. Division•of Water I-597 of the General Statutes of North Carolina.
Quality•may decide to hold a-
public meeting for the proposed This �� day of E X_ , 2001
permit should the Division
receive a significant degree of
public interest. '
Copies the draft permit
and o t h e e r supporting (Signature of person making affidavit)
information on file used to r
determine conditions resent.in
p Sworn t d subscribed before me, thiszv—/—
the draft permit are available �� , 20 i.t upon request and payment.'of _-
day of,
the costs of reproduction. Mail
comments and/or requests for;
information to the N.C,�
Division of water Quality at the Notary Public
above address or call Ms.
5083, extension 538. Please Christie Jackson at 919-733- My Commission expires: ` ��
include the NPDES permit [�
number (attached) in .any Q 1y
communication. Interested
persons may also visit the [�
Division of Water Quality at
512 N. :.Salisbury Street, v Z9
Raleigh, N.C. 27604-1.I48 �P
between the hours of
_r --and '5.00 p.m. to review_
information on file. DEN�'SC��CE
NPDES Permit Number
NC000o108, Coats American,
P.O. Box 458, Rosman, N.C.
28772 has applied for a permit
renewal for a facility located in
Transylvania- ` County
discharging treated- wastewater
into Galloway Creek in the
*French Broad River .Basin.
Currently ainmonia nitrogen are
water quality limited. This
discharge 'may affect future
allocations in this portion of the
receiving stream.
m3/12/1tc

r• ;
AFFIDAVIT OF PUBLICATION
CLIPPING OF LEGAL ADVERTISING NORTH CAROLINA
ATTACHED HERE TRANSYLVANIA COUNTY
Before the undersigned, a Notary Public of said
Copies af,the .draft permit County and State, duty commissioned, qualified, and
- �
" I ul3i.lt., NOTICE,.•��r ��# and other supporting authorized by law to administer oaths, personally
S'I'n'!'li Ui NUE2'I'!I,'} # information on file used to appeared David Phillips who being first duty sworn,
C AIn O!'.INA determine conditions present in
ENVIRONMI.NTAI. the draft -permit are available' deposes and says: that he (she) is Advertising
MANAGHWIiNT1 - upon`request-and payment'of Manager (Owner, partner, publisher, or other officer
COMMISSION/N11DE'S UNl'I' 1 the costs of re roduction.`Mail
1017 MAIL SERVICE .; p or employee authorized to make this affidavit) of
comments-and/or requests for The Transylvania Times p ,C:IiN'r1:1t . , published, issued and
information to the;. N.C.
Itni.la;11 I, N.C,. 2769i)-1617- I Division of Water Quality.at the entered as second class mail in the Town of Brevard
NOTIFICATION OF INTEINT above ' address 'or call"Ms.'
TO ISSII!?A NI)DES,-
• ., Christie Jackson at 919-733-
in said County and State; that he (she) is authorizedwAs'r1:wn'l'litz f'liltMl I' 5083, extension 538. Please to make this affidavit and sworn statement; that the
On LLthe basis 'of ihoro gh include .the ,NPDES permit notice or other legal advertisement, a true copy of
staff review and application,ofI number . .(attached)-,.in,'-any which is attached hereto, was published in The
N.C. General. Statute 143.21,i communication, .Zl -Interested
Public`I.aw 92-506 and other, poisons, may also,..visit,,ther Transylvania Times on the following dates:
lawful "`standards ` `Fand`� r '
Division of Water Quality.at March 12, 2001; , 6i
regulations, the North Carolina' 5 f 2, N-4i..,Salisbury ; Street,
Environmental Management' Raleigh,-�N.C..,�27b04,-114$
Commission proposes to issue a between the hours of 8:00 a.m.!
National Pollutant Discharge and " g 00 p:m.,,,to . review, and that the said newspaper in which such notice,
Elimination; System,,(NPDES) .information on file. •;.:. , >',
wastewater discharge permit,to ,NPDES;;'Permit-,"Nu. inber; paper, document, or legal advertisement was
the person(s) listed below NC0000108, Coats American;C published was, at the time of each and every such
effective 45 days' from the, P.O.' Box'458, Rosman, .N.C.;
publish date of this notice. ,;. , publication, a newspaper meeting all of the
Written;comments re ardin 28772 has applied' r.,a permit,.
g ga renewal fora facility located in requirements and qualifications of Section I-597 of
the' proposed. permit:awill ;be.� Tra n s y 1 y a'n"t a' 1:-�C o u nsty the General Statutes of North Carolina and was
accepted until 30,days after thei discharging treated wastewater
publish date of this notice. All are iota Galloway- Creek iri,the qualified newspaper within the meaning of Section
comments received priore •that French Broad River Basin. I-597 of the General Statutes of North Carolina.
date considered in the final Currently ammonia nitrogen are
determinations regarding the • cat
water;-:quality'-limited..'•.This / /fl�`
proposed permit. .The Director discharge;may affect future This day of /`' , 2001
of the N.C:�.Division of,Water allocations in this portion of the r
Quality may decide,to hold a i
Ft , , . f;
public meeting foi•the proposed
permit_should,-the..Division Y}` ` " ' = _;:m3/12/ltc, (Signature of person making affidavit)
receive a.significant�degree,of
public interest.. •; , y ;
Swo to subscri ed before me, this
,,day of, /,G�
Notary Public
My Commission expires:

DENR/DW Q
FACT SHEET FOR NPDES PERMIT DEVELOPMENT
NPDES No.NC0000019
k >>. > a _..,. . ._ ... ... ....... ..
pp scan acI Ity ame —Coats America
pp scant' resS " ,31'� r. leBriscoe; OX Rosman, NC 28772
aCl 1ky,' res5 Hwy Osman, NC
ermltte ow; -, 00 I+UO2 are not limited, 003 —0.015 MUD
Tpe of Waste",EDomestic, stormwater, non-contact cooling water
�aGl Ity �r1111t�- tatGS ,k k ', Active; Renewal
,ountyi, , " ransy vania
�Receiving:Stream-,;, aowai Y Creek 'Regional Icef; ,,­ Asheville
. Stream.Classl tcatton:f.nC State:(3rid:/ : : ua : osman
o Permit Writer
,:; Natalie Sierra
1/25/01
-
,<< ate., ! !
Drainage Area"(inI ) 1 0.69
Summer V s kf
inter, c s 3;3 !; ,
�()W,(qPY1.0
yerage ow c s f 1 i
Lat. 35° 10'00"N Long. 82'48'30"W
BACKGROUND
Coats America is a producer of greige (non-dyed) cotton and polyester sewing threads.
The permitted wastewater flow contains no actual process flow other than non-contact cooling
water. Sludge generated by the domestic waste at the plant is hauled off-site by DDK
Environmental and treated by the Cranston WWTP.
Outfalls 001 and 002 receive condensate from the air compressor, after cooler, air dryer,
cooling tower blowdown and air washer blowdown and cooling water. Chlorine is currently
used as a biocide,though biocide AQB-008 has been DWQ approved for use at the plant. Due to
the biocide use, the sporadic discharges from 001 and 002 are assigned an acute toxicity test.
Outfall 003 discharges domestic waste treated at he plant and is required to meet an
ammonia limit of 21.0 in addition to the more standard BOD, TSS and fecal coliform limits.
FILE REVIEW
T e As eville Regional Office has performed three inspections within this permitting
cycle. The facility has always been in compliance during these inspections, though concern has
been expressed over the chlorine contact chamber in the plant.
DMR Review:
Discharges from 001 and 002 have been extremely sporadic in recent years. The
main concern with effluent from these outfalls is acute toxicity. Outfall 002 has had three
toxicity failures in the past three years and outfall 003 has had four. Correspondence from the
last permitting cycle indicated that toxicity problems at that time were due to the biocide being
used. The biocide has since been changed, but periodic toxicity problems clearly persist.
DMRs dating from January 1997 to present were reviewed for Outfall 003. In
general, this outfall has very low effluent BOD and fecal coliform values. The facility has also
been largely compliant with the permit ammonia limit of 21 mg/L. The only cause for concern is
the exceedingly high chlorine concentration in the effluent, consistently 2200 ug/L. Although
this maintains low effluent fecal coliform numbers, this may be having an effect of chronic
toxicity on the river.
Reasonable Potential Analysis:
Reasonable Potential Analysis was not appropriate for any of the pollutants
monitored through this permit.
Fact Sheet
NPDES NC0000108 Renewal
Page l

Correspondence
Kerry Becker (ARO) completed the last staff report in 1995. This report includes a
discussion of whether or not to impose a total residual chlorine (TRC) limit on the effluent.
Toxicity for 001 and 002 was considered a sufficient indicator of negative impact of the chlorine
on aquatic life.
As mentioned previously, effluent from 001 and 002 has generated a failure of the acute
toxicity test. Notices of Violation (NOVs) have been issued for all of these and civil penalties
assessed. Four NOVs have also been issued for violations of the TSS limit on outfall 003 as well
as one violation of the ammonia limit.
A 1997 inspection report expresses concern over operation of the chlorine contact
chamber as related to very high fecal coliform counts. A 1998 inspection report recommends the
addition of baffles to the chlorine contact chamber such that high chlorine dosing is not
necessary. There is no evidence of follow through on the part of the operator, and the facility
continues to practice high chlorine dosing.
PERMITTING STRATEGY
Waste Loaa Allocafi—on--7MA).
The last waste load allocation was performed in 1991. This WLA established a limit for
ammonia of 21.0 mg/L as well as fecal coliform limits. Chlorine limits were recommended, but
after discussion with the permittee and ARO, acute toxicity testing was given instead.
SUMMARY OF PROPOSED CHANGES
The higfi a uent levels of total residual chlorine are of concern. Kerry Becker has made
several recommendations in inspection reports that attention be given to the chlorine contact
chamber. The ARO does not feel that a toxicity test or a TRC limit are in order for this outfall.
Therefore, a special condition has been imposed that requires the facility to submit and follow
through with an optimization plan for the contact chamber. If TRC values do not go down over
the course of this permitting cycle, a limit should be implemented.
PROPOSED SCHEDULE FOR PERMIT ISSUANCE
Draft Permit to Public Notice: March 14, 2001
Permit Scheduled to Issue: April 27, 2001
NPDES DIVISION CONTACT
If you have questions regarding any of the above information or on the attached permit, please contact
Natalie Sierra at(919) 733-5083 ext. 551.
NAME: DATE:
REGIONAL OFFICE COMMENTS
NAME: DATE:
SUPERVISOR: DATE:
Fact Sheet
NPDES NC0000108 Renewal
Page 2

IWC Calculations
Coats America
NCO000108
Prepared By: Natalie Sierra, NPDES Unit
Enter Design Flow (MGD): 0.015
Enter s7Q10(cfs): 0.6
Enter w7Q10 (cfs): 0.9
Residual Chlorine Ammonia (NH3 as N)
(summer)
7Q10 (CFS) 0.6 7Q10 (CFS) 0.6
DESIGN FLOW(MGD) 0.015 DESIGN FLOW(MGD) 0.015
DESIGN FLOW(CFS) 0.02325 DESIGN FLOW(CFS) 0.02325
STREAM STD (UGIL) 17.0 STREAM STD (MGIL) 1.0
UPS BACKGROUND LEVEL (U 0 UPS BACKGROUND LEVEL 0.22
IWC (%) 3.73 IWC (%) 3.73
Allowable Conc. (ugll) 456 Allowable Conc. (mg/1) 21.1
Ammonia (NH3 as N)
(winter)
7Q10 (CFS) 0.9
Fecal Limit 2001100ml DESIGN FLOW(MGD) 0.015
(If DF >331; Monitor) DESIGN FLOW(CFS) 0.02325
(if DF <331; Limit) STREAM STD (MGIL) 1.8
Dilution Factor(DF) 26.81 UPS BACKGROUND LEVEL 0.22
IWC (%) 2.52
Allowable Conc. (mg/1) 63.0
NPDES Servor/Current Versions/IWC
1125/01

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Re: Coats American(109)
Subject: Re: Coats American (109)
Date: Man, 26 Feb 2001 17:49:05 -0500
From: Kerry Becker<[e-mail]>
Organization: NC DENR - Asheville Regional Office
To: Natalie Sierra <[e-mail]>
Natalie:
Please accept my apologies for not responding sooner. Pipe 003 is
strictly domestic waste. There should be no toxicity associated with it
except for the fact that they do chlorinate but do not dechlorinate. +inAe
The chlorine usage is excessive and that is due to the chlorine contact
chamber design. I 've spoken with the plant manager about doing some
simple modifications that would take care of this. In lieu of that, eK1.5K:A; `.
dechlorinate. C% r_c
As to the other two outfalls, they are essentially one in the same. One
outfall, 001, served the wet twisting operation, cooling towers and
stormwater ,from the front half of the plant as well as the parking lot -{ fe*o kAwHa
while the other outfall, 002, served the wet twisting operation, cooling
towers and stormwater from the back half of the plant. The water from r,,"4• �s '�r
001 should be identical to the water from 002 with the exception of the CVX\0.,Z&C ,
parking lot.
The wet twisting operations no longer exist and should be removed from
the descriptive portion of the permit if it has not already been done.
This operation was never the source of the original toxicity. We found
out that the source was the cooling towers. Nine months of the year,
Coats, at that time, was using a biocide 9 months of the year and
chlorine 3 months of the year. Eddie Briscoe, the plant manager,
thought it was 9 months chlorine and 3 months biocide for some time
before we realized his mistake. Once we did, we changed the biocide and
the toxicity stopped. It showed up again in Feb. 2000 after the
maintenance crew had put salts and deicing chemicals on the parking lot
just before they sampled for toxicity. The obvious happened.
The last tox occurred in August 2000. The cause could not be determined
except for the possibility of residual biocide contaminants coupled with
the fact that the flows from these pipes are substantially less than
when the wet twisting operations were running. Stormwater run off is
probably a big factor in toxicity from these discharges. I 'd like to
check it for a while to confirm it but then that would open up another
can of worms.
Kerry
Natalie Sierra wrote:
> Kerry-
> Have you gotten a chance to look at the draft for Coats yet? I was
> wondering what you think about a potential tox requirement on the
> outfall that doesn 't have one. Let me know.
> Thanks,
> Natalie
Kerry Becker - [e-mail]
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]
1 of 2 2/27/01 8:56 AM

coats american
Subject: coats american
Date: Fri, 26 Jan 2001 13:39:50 -0500
From: Kevin Bowden <[e-mail]>
To: Natalie Sierra<[e-mail]>
CC: Kristen Robeson <[e-mail]>,
Matt Matthews <Matt.Matthews@ncma i 1.net>
Natalie, attached is proposed tox. test condition language. As
discussed, we would support grab samples versus composite at 001 and
002.
After looking over the fact sheet I have a question. High residual
chlorine values have been reported for 003. You recommended that
consideration be given to placing a chlorine limit in the permit or
downstream monitoring for 003. How much data do you require to
impose a C12 limit? Is there any merit to having ARO pull a tox
sample on 003? My concern is that 003 may be adversely
affecting aquatic life in the receiving stream. thanks. kevin.
Name: QAL coats american PF pulex or
cerio 24.doc
r1 AL coats american PF pulex or cerio 24.doc Type: Microsoft Word Document
(app l i c ati o n/m s word)
Encoding: base64
Download Status: Not downloaded with message
I of 1 1/26/01 3:23 PM

c
Coats North America
P,O. Box 670
Coats Toccoa, Georgia 30577
Telephone: [phone]
North America FAX: [phone]
March.24, 2000
Ms:'Chrystie R. Jackson
De' artmerrt`of Environment and Natural Resources
Division of Water Quality
1617 Mail Service Center MAR 2 7 200Q
Raleigh,NC 27699-1617
L.
Re: NPDES Permit Renewal Application PO ;�;�;; �;�
Permit NC00001'080
Coats American, Sylvan Plant
Transylvania County
Dear Ms. Jackson:
As requested in your March 7, 2000 letter, subject as above, enclosed is a copy of the Coats
American- Sylvan Plant's Sludge Management Plan.
Please advise should you have any,questions.or comments about this plan or the permit renewal
application.
„Sincerely,
COATS NORTH AMERICA
o—) I�eQDP
Mike Bell
Enclosure
cc: Eddie Briscoe - Sylvan Plant
NC-DEHNR Asheville Regional Office, Water Quality Section
Syl Sludge Plan-Xmt.lwp
A member of the Coats Viyella.Group

M
Coats American
US Hwy 178
• Coats American P Q
Roo smansman,, IVC 28772
Telephone: [phone]
Fax: [phone]
Sludge Management Plan
I. General Information
A. Name/Address of Regulated Entity: Coats American, US Hwy 178, PO Box 970,
Rosman,NC 28772
B. Contact: Eddie Briscoe, Plant Engineer, [phone], Ext. 17
C. Applicable Permit: NPDES #f NC0000108
D. System Description: The plant treats primarily sanitary sewage via a 15,000 gallon per
day (.015 MGD) extended aeration package wastewater treatment system with effluent
disinfection to discharge at Outfall No. 003. The plant also discharges noncontact
cooling water combined with stormwater at OutfalIs No. 001 and No. 002. All outfalls
discharge into Galloway Creek in the French Broad River Basin.
11. Sludge Generation & Management:
A. Sludge Generation: Sludge is generated as a result of biologic activity and extended
aeration of the sanitary wastewater generated at the plant. This sludge producing
wastewater is treated and discharged only via Outfall No. 003. Approximately 2500
gallons of sludge are generated every six months and held in the aeration basin of the
system pending periodic disposal.
B. Sludge Management: The Wastewater System Operator measures the settlable solids
every week, or as needed by visual inspection, utilizing a 1000ml flask within a 30
minute time period test method. After exceeding 500m111000ml settled solids in 30
minutes, a licensed environmental contractor is utilized to vacuum the sludge from the
aeration basin and transport the waste to an approved disposal site.
C. Sludge Disposal Contractor: The current contractor used for sludge removal is:
DDK Environmental Inc.
1 King Road Address
Pisgah Forest, North Carolina
Phone: [phone]
Pumping/Hauling Permit/License No: HCHDNCS00302

ti
Sludge Management Plan
Coats American
Sylvan Plant - Rosman, North Carolina
D. Sludge Disposal Site:
Cranston WWTP
Highway 25
Fletcher, NC
Phone No. NIA
EPA ID No. NC0000094
E. Recordkeeping: Copies of all records confirming the date and quantity of sludge
removed and disposed from the wastewater treatment system will be returned to the Plant
Engineer and maintained for at least three years.
-C'U L-
Eddie Briscoe
Plant Engineer
March 24, 2000
Page 2 of 2

Coats North America
P.O. Box 670
Coats Toccoa,Georgia 30577
North America Telephone: [phone]
FAX: [phone]
o x
February 24, 2000
�� C]C�
i rn L-f".)
N' 'r
r
co
� LX f
N.C. Department of Environment and Natural Resources i
Division of Water Quality/NPDES Unit
1617 Mail Service Center
Raleigh,NC 27699-1617
Reference: NPDES Permit Renewal
Rosman, NC
Coats American, Sylvan Plant
Permit No. NC 0000108
Enclosed is the renewal application for the NPDES Permit for the above noted plant. Please
advise if you require additional information.
Yours very truly,
COATS NORTH AMERICA
1 It
Mike Bell
Environmental Engineer
MBilm
Enclosures
CC: Mr. Keith Lyerly
Mr. Eddie Briscoe
A member of the Coats V*1la Group

SCHEMATIC OF WASTE WATER FLOW
COATS AMERICAN - SYLVAN PLANT
TRANSYLVANIA COUNTY
ROSMAN, NORTH CAROLINA
NPDES PERMIT NO. NC0000108
POTABLE WATER PACKAGE
TREATMENT OUTFALL 003
CHLORINATION PLANT (AERATION)
FOR DISINFECTION
NON-CONTACT
COOLING WATER
•AIR COMPRESSOR OUTFALL 002
AFTERCOOLER
• AIR DRYER
CONDENSER
COOLING WATER
CHLORINATION
AS BIOCIDE
COOLING
TOWER
BLOWDOWN
BLOWDOWN
AIR WASHERS
SLOWDOWN OUTFALL 001
2-24-2000

State of North Carolina
Department of Environment,
Health and Natural Resources 4
Division of Water Quality
James B. Hunt, Jr., Governor
Jonathan B. Hawes, Secretary N F�
A. Preston Howard, Jr., P.E., Director
August 6, 1996
Mr. Bill Merritt
Water Technology and Controls, Inc.
P.O. Box 8808
Greensboro, North Carolina 27419
Subject: Biocide Approval Request
Permit: NCO000108
Transylvania County
Dear Mr. Merritt:
The Division of Environmental Management has received your request dated
May 17, 1996 for approval of the biocide AQB-008 at the Coats-American Plant in
Rosman, NC. Attached please find a copy of the report from the Aquatic Survey &
Toxicology Unit. After a review of the biocide information you submitted, the
Division has concluded that use of AQB-008 is deemed acceptable at the stated rates
and dosage levels.
If you have any questions regarding this matter, please contact Charles
Weaver at [phone], ext. 511.
Sincerely,
David Goodrich
Supervisor, NPDES Group
cc: Central Files
Asheville Regional Office
(Permits&Engirieering-Unit
P.O. Box 29535, Raleigh, North Carolina 27626-0535 Telephone[phone] FAX [phone]
An Equal Opportunity Affirmative Action Employer 50% recycled 110%post-consumer paper

Division of Water.Quality
July 19, 1996
n
r�
f..
MEMORANDUM
- J
f
To: Dave Goodrich
P
From: Melissa Rosebrock
Through; Matt Matthews
Subject.: Biocide Use at Coats American
NPDES# NC0000108 (001 and 002)
Transylvania County
We have reviewed the Biocide Form 101 for AQB-008 submitted by the chemical supplier on behalf of
Coats American. As the facility currently operates outfalls 001 and 002 with acute toxicity monitoring
requirements and limits, the whole effluent toxicity tests should'r rovide validation that acute toxicity of
the effluent is acceptable. Thes-efore, approval from this office is not necessary for biocide use at
outfalls 001 and 002. If I can provide you with further informatio;l, please call me at [phone].
attachment
cc: Central files
Forrest Westall-ARG
/* Environmeniul Sciences Branch Water Quality Section.