NC0023604_Permit Issuance_19990426

NPDES DOCUMENT SCANNING COVER SHEET
NC0023604
NPDES Permit:
Document :
Permit Issuance',
Wasteload Allocation
Authorization to Construct (AtC)
Permit Modification
Complete File
- Historical
Engineering Alternatives (EAA)
Plan of Action
Instream Assessment (67b)
Speculative Limits
Environmental Assessment (EA)
Permit
History
Document Date:
April 26, 1999
This document is printed on reuse paper - ignore a,ny
content on the reireriee side

State of North Carolina
Department of Environment
and Natural Resources
Division of Water Quality
James B. Hunt, Jr., Governor
Wayne McDevitt, Secretary
Kerr T. Stevens, Director
April 26, 1999
Ms. Miki Ford
Thomasville Furniture Industries, Inc.
Post Office Box 339
Thomasville, North Carolina 27361-0339
Dear Ms. Ford:
NCDENR
NORTH CAROLINA DEPARTMENT OF
ENVIRONMENT AND NATURAL RESOURCES
Subject: Final NPDES Permit
Permit No. NC0023604
SFD/64 Lumber Plant
Davidson County
In accordance with the application for a discharge permit received on February 18, 1998, the Division is
forwarding herewith the subject NPDES 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 December 6, 1983, and as subsequently amended.
Please note the following changes from the previous permit (as indicated in the draft) have been finalized:
• Wastewater plant description has been revised, in accordance with the Authorization to Construct
(ATC) issued 12/1/95.
• Ammonia limits have changed to 2.0/4.0 mg/I (S/W). It is Division policy not to impose ammonia
limits more stringent than 2/4 mg/1 on minor facilities, unless ammonia is limited for oxygen -
consuming reasons.
• Effluent temperature monitoring has changed to daily, in accordance with most recently updated
T15A: NCAC 2B .0500s.
• Instream conductivity monitoring has been removed. Conductivity measures inorganic
contaminants, and data from this facility indicated monitoring is not necessary.
• Quarterly monitoring for total nitrogen and phosphorus has been added. This change is
consistent with an effort to gather more data about nutrient loading in this portion of the watershed.
• Uutfall 002 has been added to the permit and addresses the discharge of kiln condensate. This
change is consistent with the renewal application received February 24, 1999, and requirements are
similar to what would be required under a general permit for this type of discharge.
In response to your verbal comments of April 21, 1999:
• The typographical error in the third footnote on effluent page A(2). has been corrected.
• Although a limit range for pH is specified on effluent page A(2)., no monitoring is required.
• Monthly reporting requirements are still in effect, as specified by the boiler plate language contained
in the final permit.
P.O. Box 29535, Raleigh, North Carolina 27626-0535 Telephone [phone]/FAX [phone]
An Equal Opportunity Affirmative Action Employer 50% recycled/ 10% post -consumer paper

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, Post Office Drawer 27447, Raleigh, North Carolina 27611-7447. Unless such demand is made,
this decision shall be final and binding.
Please take note that this permit is not transferable. Part II, E. 4. addresses the requirements to be
followed in case of change in ownership or control of this discharge. This permit does not affect the legal
requirements to obtain other permits which may be required by the Division of Land Resources or any
other Federal or Local governmental permit that may be required.
If you have any questions or comments concerning this permit, please contact Bethany A. Bolt at (919)
733-5083, extension 551.
Sincerely,
Original Signed By
David A. Goodrich
Kerr T. Stevens
Enclosure
cc: Winston-Salem Regional Office/Water Quality Section
Central Files
NPDES Unit
Mr. Roosevelt Childress, EPA
Point Source Compliance Enforcement Unit

Permit No. NC0023604
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,
Thomasville Furniture Industries, Inc.
is hereby authorized to discharge wastewater from a facility located at
SFD/64 Lumber Plant
7578 US Highway 64
Lexington
Davidson County
to receiving waters designated as an unnamed tributary to Flat Swamp Creek in the Yadkin -Pee
Dee 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 June 1, 1999.
This permit and authorization to discharge shall expire at midnight on May 31, 2004.
Signed this day, April 26, 1999.
Original Signed By
David A. Goodrich
Kerr T. Stevens, Director
Division of Water Quality
By Authority of the Environmental Management Commission

Permit No. NC0023604
SUPPLEMENT TO PERMIT COVER SHEET
Thomasville Furniture Industries, Inc.
is hereby authorized to:
1. Continue to operate an existing 0.0125 MGD extended aeration wastewater treatment
facility, consisting of an aeration chamber, sludge holding tank, clarifier, recirculating
sand filter, 5:1 flow splitter, 1500-gallon recirculation tank with air diffuser, filter
screens, dual pumps, tablet chlorination and dechlorination, and a fifty-four (54) day
polishing pond, located at SFD/64 Lumber Plant, US Highway 64, Lexington,
Davidson County, and
2. Discharge domestic wastewater and boiler blowdown from outfall 001, and
3. Discharge kiln condensate from outfall 002, and
4. Discharge from said treatment works at the location specified on the attached map
into an unnamed tributary to Flat Creek Swamp, which is classified as C waters in the
Yadkin -Pee Dee River Basin.

SCALE 1:24000
Latitude: 35%6'2130"
Longitude: 8097'12"
Quad #: D18SE, "Fair Grove"
Stream Class: C
Receiving Stream: UT to Flat Swamp Creek
Facility
Location
North
SFID/ 64 Lumber Plant
NC0023604
Davidson County

A (1). EFFLUENT LIMITATIONS AND MONITORING REQUIREMENTS r,tIN ; t.-[;,,
Permit No. NC0023604
During the period beginning on the effective date of the permit and lasting until expiration, the Permittee is authorized to discharge domestic
wastewater and boiler blowdown from outfall(s) serial number 001. Such discharges shall be limited and monitored by the Permittee as
specified below:
EFFLUENT CHARACTERISTICS ti ..3? y
P LIMITS - _ - _ •, :
. _' MONITORING RE UIREMENT
i
Average
: WeeklyDaily
Average
Maximum'
Measurement
'Frequency
:Sam le'
- Tpe •
. Scam le
Loation ::..
Flow
0.0125 MGD
Weekly
Instantaneous
I or E
BOD, 5 day, 20°C (April 1 - October 31)
5.0 mg/1
7.5 mg/1
Weekly
Grab
E
BOD, 5 day, 20°C (November 1 - March 31)
10.0 mg/1
15.0 mg/1
Weekly
Grab
E
Total Suspended Solids
30.0 mg/1
45.0 mg/1
Weekly
Grab
E
NH3 as N (April 1 - October 31)
2.0 mg/1
Weekly
Grab
E
NH3 as N (November 1 - March 31)
4.0 mg/1
Weekly
Grab
E
pH1
Weekly
Grab
E
Dissolved Oxygen2
Weekly
Grab
E, U, D
Fecal Coliform (geometric mean)
200/100 ml
400/100 ml
Weekly
Grab
E
Total Nitrogen (NO2 + NO3 + TKN)
Quarterly
Grab
E
Total Phosphorus
Quarterly
Grab
E
Total Residual Chlorine
17 µg/ 1
2/Week
Grab
E
Temperature °C3
Daily
Grab
E
Temperature °C
Weekly
Grab
U, D
Notes:
* Sample locations: E - Effluent, I - Influent, U - Upstream at least 100 feet, D - Downstream at least 300 feet.
i The pH shall not be less than 6.0 standard units nor greater than 9.0 standard units.
2 The daily average dissolved oxygen effluent concentration shall not be less than 6.0 mg/1.
3 The temperature of the effluent shall not cause an increase in the temperature of the receiving stream of more than 2.8°C and in no case
cause the ambient water temperature to exceed 32°C.
There shall be no discharge of floating solids or visible foam in other than trace amounts.

A (2). EFFLUENT LIMITATIONS AND MONITORING REQUIREMENTS V.1I Aj
Permit No. NC0023604
During the period beginning on the effective date of the permit and lasting until expiration, the Permittee is authorized to discharge kiln
condensate from outfall(s) serial number 002. Such discharges shall be limited and monitored by the Permittee as specified below:
Monthly
:Average
Flow
pH1
Weekly
Average
Daily
Maximum
MONITORING REQUIREMENTS
Measurement
,Frequency .,
Semi-annually
N/A
Sample
Type
Estimate
Grab
Sample
Location*
E
Total Residual Chlorine2
Semi-annually
Grab
Temperature °C3
Semi-annually
Grab
Notes:
* Sample locations: E - Effluent
i The pH shall not be less than 6.0 standard units nor greater than 9.0 standard units.
2 Monitoring requirements apply only if chlorine is added to the treatment system.
3 The temperature of the effluent shall not cause an increase in the temperature of the receiving stream of more than 2.8°C and in no case
cause the ambient water temperature to exceed 32°C.
THERE SHALL BE NO CHROMIUM, ZINC, OR COPPER ADDED TO THE DISCHARGE EXCEPT AS PRE -APPROVED ADDITIVES TO
BIOCIDAL COMPOUNDS.
The Permittee shall obtain authorization from the Division prior to the use of any chemical additive in the discharge. The Permittee
shall notify the Director in writing at least ninety (90) days prior to instituting use of any additional additive in the discharge which
may be toxic to aquatic life (other than additives previously approved by the Division). Such notification shall include completion of
Biocide Worksheet Form 101 (if applicable), a copy of the MSDS for the additive, and a map indicating the discharge point and
receiving stream.
There shall be no discharge of floating solids or visible foam in other than trace amounts.

State of North Carolina
Department of Environment
and Natural Resources
Division of Water Quality
James B. Hunt, Jr., Governor
Wayne McDevitt, Secretary
A. Preston Howard, Jr., P.E., Director
March 3, 1999
Ms. Miki Ford
Thomasville Furniture Industries, Inc.
Post Office Box 339
Thomasville, North Carolina 27361-0339
Dear Ms. Ford:
v3,2
Subject: Draft NPDES Permit
Permit No. NC0023604
SFD/64 Lumber Plant
Davidson County
ArA
NCDENR
NORTH CAROLINA DEPARTMENT OF
ENVIRONMENT AN D NATURAL RESOURCES
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Enclosed with this letter is a copy of the draft permit for the above referenced facility. I encourage you to
review these documents very carefully to ensure thorough understanding of the information, conditions,
and requirements contained therein.
You should be aware that the following changes have been incorporated into your permit:
• Wastewater plant description has been revised, in accordance with the Authorization to Construct
(ATC) issued 12/1/95.
• Ammonia limits have changed to 2.0/4.0 mg/1 (S/W). It is Division policy not to impose ammonia
limits more stringent than 2/4 mg/1 on minor facilities, unless ammonia is limited for oxygen -
consuming reasons.
• Effluent temperature monitoring has changed to daily, in accordance with most recently updated
T15A: NCAC 2B .0500s.
• Instream conductivity monitoring has been removed. Conductivity measures inorganic
contaminants, and data from this facility indicated monitoring is not necessary.
• Quarterly monitoring for total nitrogen and phosphorus has been added. This change is
consistent with an effort to gather more data about nutrient loading in this portion of the watershed.
• Outfall 002 has been added to the permit and addresses the discharge of kiln condensate. This
change is consistent with the renewal application received February 24, 1999, and requirements are
similar to what would be required under a general permit for this type of discharge.
Please review the draft permit carefully and submit any comments to David Goodrich no later than thirty
(30) days following receipt at the following address:
NCDENR
DWQ/Water Quality Section
NPDES Unit
Post Office Box 29535
Raleigh, North Carolina 27626-0535
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P.O. Box 29535, Raleigh, North Carolina 27626-0535
An Equal Opportunity Affirmative Action Employer
Telephone [phone]/FAX [phone]
50% recycled/ 10% post -consumer paper

•
If you have any questions or comments concerning this draft permit, please contact Bethany A. Bolt at
[phone], extension 551.
Enclosure
cc: NPDES Unit
e1y,
isi Da ud A. Goodrl Supervisor
NPDES Unit

•
• ,cribed ,
..ea permit.
. copy of the draft permit is
available by writing or call-
; ing the Division of Environ-
, mental Management, P.O.
- Box 29535, Raleigh, North
Carolina 27626-0535, (919)
733-7015.
• -' The application and other in-
formation may be=inspected
at these locations during nor-
mal office hours. Copies of
the information on file are
available upon request and
•payment of the costs of
:reproduction. All such com-
ments or requests regarding
a • proposed permit should
make reference to the
NPDES permit number list-
ed below. .
:Date March 8,1999
• David A. Goodrich
A. Preston Howard Jr., P.E.,
. Director
• Division of
. Environmental Management
Public notice of intent to is -
:sue a State NPDES permit to
•the following:
:1. NPDES No. NC0031950.
•Davidson County Board of
Education, PO Boa 2057,
Lexington, 'NC 27293 has
applied for a permit renewal
'for a facility located at West
.Davidson High School, off
• -NCSR 1213, east of Tyro,
: ;Davidson County. The fa-
- icility discharges 0.007 MGD
'of treated domestic wastewa
• 'ter from one outfall into an
: , unnamed tributary to North
• Potts Creek, a Class C
' stream in the Yadkin -Pee
Dee River Basin idrich:has a
' '1Q10 flow of 0 cfs• and a
i 30Q2 flow of 0 cfs: Ammo-
• • ► •nia, BOD5 and' dissolved
oxygen are water'. ' quality
limited. For some parame--
. tern, the available load ca-
- • pacity of the immediate
: ; receiving water will be con-
•- ► sumed . This may affect
. ' future water quality based
I • `• effluent limitations for addi
' tional dischargers. within this
: i portion of the watershed- •;
- 1: • t. 'l.�. C''
.. ; 2. NPDES No. NC0070637.
Kurz and Partners,' L.P.;
4939 North NC : Highway
•• • 150, Lexington, NC 27292
•_ " has applied for a permit re-
- . newal for a facility located at
- - • Kurz Transfer Products;
• : 4939 North NC Highway
t ' ' 150, Lexington; • Davidson
- . County, The.. facility dis- .
- • charges 0.0015 MGD of
• " treated domestic wastewater
• from outfall 001 and boiler
blowdown from ' outfall 002-
• . This discharge is to an un-
named tributary to . Reedy
.'. Creek, a Class WS-IV
- stream in the Yadkin -Pee
' Dee River Basin which has a
7Q10 flow of 0.91 cfs. No
- ' • parameters are water quality
' limited, but this discharge
. may affect future waste load
• r•r tlocations. : • ••
1. NPDES No. NC 0023604.
: 1'homasville ; Furniture', In -
from one outfall into an un-
named tributary to Abbotts
Creek, a Class WS V & B
steam in the Yadkin -Pee Dee
River Basin which has a
7Q10 flow of 0 cfs and a'
30Q2 flow' of 0 -cfs. Ammo-
'nia, • BOD5 = ead""dissolved'
oxygen-. are water. quality:
limited. or some.. parame-
ters,7 tile''' rt arable load
.capacity;^ of the:. immediate
iv
receing wafer:will be con-
samed. •1. This.: may affect
future • .water, quality based
effluent limitations for addi-.
tional dischargers, within this
portion of theyerershed, ' }
6. NPDES,, No NC0029947.'
Davidson'+. CEiunty Schools;
PO • Box ° 2057; ., Lexingtont�.
NC 27293 has: applied for; a
permit renevia1 for a facility
located at Davidson Co Sch-
Churchland Elern; NC Hwy
150, Churchland, )Qavidson
County.'; 'the:, facility " dis
charges ' 0.0037 •• MGD ;. of
treated domestic wastewater
from one uutfallinto-an; un-
named.- tn'but$ry South
Potts Creek, a Class C
stream': iny= the.`,Yadkin-Pee.
Dee River Basin which has a
7Q10 flowof 0"'cfs and 'a`
30Q2 flow, of 0 cfs. Ammo-
nia, BOD5 and: dissolved.
oxygen • are' water quality
limited. For some parame-
ters, the available load
capacity of the immediate
receiving water will be con-
sumed. This may affect
future water quality' based
effluent limitations for addi-
tional dischargers within this
portion of the watershed.
Road, Clemmons, Davidson
County. The facility dis-
charges 0.100 MGD of treat-
ed .' domestic _ wastewater
from one outfaff into the --
Yadkin River a Class WS-
IV. stream in the Yadkin -Pee •S>rai
Dee River Basin l which has a
7Q10 flowof 552 --cfs. The °r,•,
facility, is • permitted for an::
et,‘,
N
• w
• w
• w
• w
• 440
ultimate expagsion-to. 0,140
MGD:. Now parameters::. are.
water : quality::.limited;; but
this discharge rosy affect fu-
ture allocations:`;. r "''•
11.= NPDES No.1NC0083941.
Heater Utilities, Inc: PO Box
29535, Cary, NC 27519 ' has
applied for a permit renewal
for a.: facility located at
Spring' t Creek Subdivision,
Central . Road, . Clemmons,
Davidson' County. The fa-
cility • discharges 0.08 MGD
of treated domestic wastewa-
ter. from. one outfall into
Fryes Creek; 'a. Clasi WS-IV
stream •: in"• the :Yadkin -Pee
Dee River Basin which has a
7Q10flow of0.64cfs and a_
30Q2flow„_of- 2.03. cfs.
Ammonia 'is. water ' quality
limifed;- and:. this 'discharge
may. affect future waste load
allocations. ' ..•
March 10,1999..
7: NPDES No. NC0042056.
Davidson`: CoimtyY Board of
Education,: PO: Box 2057,
Lexington' NC,!,,,27293. has,
applied for apeimit renewal
for a facility located at
Davidson County Schools -
Tyro Middle School, NCSR
1215, southeast_of Tyro, Da-
vidson County:..The facility.
dischargesV 0.005 MGD . of
treated domestic wastewater
from one - ended into an` ua-
named ,tributary, . to North
Potts ' Creek, a a : Class C
stream 'in the' -.Yadkin -Pee
Dee River Basin which has a.
7Q10 flow of. 0; cfs and a
30Q2 flow of 0 cfs. Ammo-
nia, BOD5 and dissolved...
oxygen are water quality'•
limited.- .For: some parame-
ters, the available load' ca- '
pacirj of ...the., immediate
receiving water, will be con-
sumed. 'Timis may : affect
future water quality based
effluent limitations for addi-
tional dischargers•.within this •-
portion of the watershed.
,s s re
8. NPDES No. NC0041602:
Davidson County Board of
Education, . PO,..Box 2057;
Lexington, NC 27293 has
applied for a permit renewal
for a facility located at Da
vidson County Schools- Sit;
vex.. Valley . Elementary; . in-
tersection • of NCSR'• 2416 &
NCSR 2205, Denton, David-
son County. The facility
s

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AFFIDAVIT OF PUBLICATION (( j
STATE OF NORTH CAROLINA Lexington,N.C. v ' OAJ JL l v 191 G 1
DAVIDSON COUNTY
of THE DISPATCH, a newspaper published in the city of
7 Q of
Lexington, County and State aforesaid, being duly sworn, says the foregoing
which the attached is a true copy, was published in said newspaper once the I 0
day of In th
Sworn to and subscribed before me, this
199 . , J 0 ��/
Publication Fee $ -T 09
•E (Seal)
io day of /f/�.rc�-'L'_F-�•'' e�f�;,
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Staff Review and Evaluation
NPDES Wastewater Permit (NC0023604) Fact Sheet
I
Facility Information
Facility Name:
Thomasville Furniture Industries, Inc. (SFD/64 Lumber Plant)
NPDES No.:
NC0023604
Permitted Flow (MGD):
0.0125
County:
Davidson
Facility Class:
II
Regional Office:
Winston-Salem
Facility/Permit Status:
(i.e. New, Modification, Existing or
Renewal)
Renewal
USGS Topo Quad:
DI8SE, "Fair
Grove"
Stream Characteristics
Receiving Stream:
UT to Flat Swamp Creek
303(d) Status:
Not Listed (No Use -support Rating)
Stream Classification:
C
Winter 7Q10 (cfs):
0.0
Subbasin:
03-07-04
30Q2 (cfs):
0.0
Drainage Area (mi2):
1.49
Average Flow (cfs):
1.4
Summer 7Q10 (cfs)
0.0
IWC (%):
100
Proposed changes:
Location
Proposed Changes
Basis for changes
Cover Page
Updated location of facility.
Renewal application.
Supplement to Cover
Updated description of treatment
system.
12/1/95 ATC issued for
recirculating sand filter.
Effluent Limitations and
Monitoring Requirements
Changed ammonia limits to 2/4
mg/1(S/W).
Division policy for minor facilities
not to impose ammonia limits more
stringent than 2/4.
Effluent Limitations and
Monitoring Requirements
Created additional effluent page
addressing kiln condensate flow
from outfall 002 (SW-2
stormwater drain).
Facility reported kiln condensate
being discharged at outfall 002
(stormwater drain SW-2). Similar
to general permit requirements for
condensates.
Effluent Limitations and
Monitoring Requirements
Effluent temperature monitoring
changed to daily.
Updated 2B .0500s.
Effluent Limitations and
Monitoring Requirements
Conductivity monitoring
removed.
No trend in conductivity observed
in instream data over past two
years; conductivity used to measure
inorganic contaminants, which are
probably not present.
Effluent Limitations and
Monitoring Requirements
Quarterly total nitrogen (TN) and
phosphorus (TP) monitoring
added.
Per 12/7/98 Memo from Steve
Pellei outlining nutrient monitoring
strategy for Yadkin sub -basins.
Compliance Schedule: N/A.
Special Condition(s):
N/A.
1
03/02/99
N.C.RFC AIM
R
MAR - 5 1999
Winston- zieCn
Regional Office

Staff Review and Evaluation
NPDES Wastewater Permit (NC0023604) Fact Sheet
Compliance History
• 11/6/96 Compliance inspection report noted these violations, among others; however, it also noted
that no violations were noted for the previous 3 months, coinciding with the installation of tertiary
sand filters (as required by SOC that expired 11 / 1 /96).
• 2 NOVs for ammonia in '97. 1 NOV for ammonia issued in '98.
• 1/7/98 letter from WSRO responded to a request from the facility to place the polishing pond back
into service to aid in nitrification/denitrification. Letter stated that no violations had occurred since
3/97, since supplemental organic matter (dog food) was being added to the plant —the average flow
had been _only 600 gpd (well under design of 12,500 gpd), and so organic matter was seriously
lacking. RO asserted that because data was trending towards consistent compliance, it was hesitant to
endorse a large process change, but would allow pond temporarily to be put into service on a trial
basis.
• Flows average 600 gpd. Temps. and pH data fine. TRC below detect (0.015 mg/1), and fecal
normally <1/100 ml. TSS <5.0 mg/1.
• Effluent DOs around 7-9.5 mg/1, depending on season. BODS normally <3 mg/1 (often <1.00).
• Ammonia higher in early '97 (as high as 9-12 in 1/97), but then usually <0.5 mg/1 the remainder of
the year. Appeared to begin same trend in '98, but fell <1 mg/1 the rest of the year.
• Instream data: No trend in conductivity, temperature, or fecal. Several instances of no flow. DO
measurements are the same or slightly higher downstream than those upstream. Some levels were
recorded below the standard (4-5 mg/1) during summer low flow conditions.
Additional Comments
• Basinwide plan contains no specific strategies applicable to this discharge. There are no ambient
stations in this area.
• Pursuant to permit requirement, EAA was submitted on 2/14/95, and upon review, DWQ concurred
that upgrading the existing plant was the best alternative via letter on 7/7/95.
• 8/21/95 letter denied an extension of the deadline for compliance with a non -discharge alternative,
since an ATC had not been issued.
• SOC issued 6/17/96 (required tertiary filter installation).
• Facility originally applied for coverage under the general permit; however, since domestic waste is
discharged, all discharges will remain in an individual permit.
• Per Jimmy Wilson at the plant, kiln condensate is being discharged through SW-2 (stormwater drain)
at a rate no more than 30 gpd. He has noted this discharge in previous permit applications, however,
the outfall was never addressed in the permit. Condensate builds up inside the steam coils used to dry
the lumber in large kilns and never comes in contact with the wood, so waste is not oxygen
consuming.
Proposed Schedule:
Draft Permit to Public Notice: 3/3/99
Permit Scheduled to Issue: 4/26/99
State Contact
If you have any questions on any of the above information or on the attached permit, please
contact Bethany Bolt at [phone], extension 551.
2
03/02/99

Staff Review and Evaluation
NPDES Wastewater Permit (NC0023604) Fact Sheet
Copies of the following are attached to provide further information on the permit development:
• Renewal Applications
• Existing Permit
NPDES Recommendation by:
Regional Office Comments: f, �,,� t� �/ �,., �� L "�, cA-,c
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,to tJPb S fat , f Nu C Oo a3 ,o(-1. L AZ R 0 A cnx/nc_e x °C.i )
Regional Recommendation by:
Reviewed By:
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03/02/99

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AS PER NORTH CAROLINA GENERAL STATUE 130A 335(e) AND JAN 1, 1990 AMENDMENT
OF THE NORTH CAROLINA ADMINISTRATIVE CODE TITLE 15A NCAC 18A.1952 (b)(2)(A-E)
THE SEPTIC TANK SYSTEMS WILL BE DESIGNED TO MEET THE FOLLOWING MINIMUM
CAPACITIES:
FLOW OF LESS THAN 600 GALLONS PER DAY ==>
VOLUME OF TANK = 2 * DAILY GALLONS PER DAY FLOWRATE
VOLUME OF TANK 1 = 1000 GAL; THEREFORE, FLOWRATE = 500 GAL PER DAY
VOLUME OF TANK 2 IS UNKNOWN, BUT KNOWN TO BE LESS THAN VOLUME OF TANK 1.
PER 15A NCAC 18A.1952 (b)(3) THE MINIMUM TANK SHALL BE GREATER THAN 750
GALLONS CAPACITY. THEREFORE, FLOWRATE MUST BE AT LEAST 375 GAL PER DAY.
ASSUME FLOWRATE IS BETWEEN 375-500 GAL PER DAY.
AVERAGE FLOW THROUGH WASTEWATER TREATMENT PLANT IS 580 GAL PER DAY.
AVERAGE BOILER BLOWDOWN IS 20 GAL PER DAY.
AVERAGE MONTHLY USAGE OF WATER AT THE FACILITY IS 571,000 GAL.
ASSUMING 30 DAYS IN A MONTH, DAILY AVERAGE WATER USAGE IS 19033 GAL.
CALCULATE KILN CONDENSATE DISCHARGE (ASSUME ALL UNACCOUNTED WATER
USAGE IS FROM KILNS):
19033 GAUDAY WATER USAGE
580 GAUDAY SANITARY DISCHARGE
1000 GAUDAY TO SEPTIC TANKS
20 GAUDAY BOILER BLOWDOWN
17433 GAUDAY KILN CONDENSATE DISCHARGE

State of North Caroling
Department of Environment,
Health and Natural Resources
Division of Environmental Management
James B. Hunt, Jr., Governor
Jonathan B. Howes, Secretary
A. Preston Howard, Jr., P.E., Director
March 31, 1995
Ms. Sherry Stoockey
Thomasville Furniture
P.O. Box 339
Thomasville, North Carolina 27361
Dear Ms. Stookey:
The Division of Environmental Management staff have reviewed the Non -Discharge Alternatives Evaluation
Report for the Thomasville Furniture Industries submitted by your firm and dated February 10, 1995. The.
Division concurs with the conclusion that all non -discharge options investigated in the report are currently not
feasible. Thomasville Furniture may elect to submit an Authorization to Construct to upgrade the existing
wastewater treatment plant. However, please be advised that the facility will be required to tie on to municipal
sewer service as soon as it becomes available regardless of improvements to the existing system.
Aglalthargatizatink
EI
allEffiScifiEZLIEVEk
Subject: NPDES Permit Modification
and Alternative Analysis
NPDES Permit NC0023604
Thomasville Furniture
Davidson County
The Non -Discharge Alternative Evaluation also included a request to increase ammonia nitrogen limits to 2 ing/I
summer and 4 mg/1 winter. The Division supports this request. In accordance with this determination, your
NPDES permit has been modified to reflect the appropriate changes_
Attached to this correspondence is an amended "EFFLUENT LIMITATIONS AND MONITORING" page which
should be inserted into your permit. The old effluent limitations and monitoring page should be discarded. All
other terms and conditions contained in the issued permit remain unchanged and in full effect. These permit
modifications are issued pursuant to 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. This
permit modification becomes effective immediately.
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, Post Office Drawer 27447, Raleigh,
North Carolina 27611-7447. Unless such demand is made, this decision shall be final and binding.
If you have any questions, please contact Jeanette Powell of my staff at [phone], extension 537.
Sincerely,
//
/ d�L"CUV
. Preston Howard, Jr., P.E.
w/attach
cc: Central Files
Winston Salem Regional Office, Water Quality Section
Mr. Roosevelt Childress, EPA
Permits and Engineering Unit
Facilities Assessment Unit
David Weyman, ESE Environmental, Inc.
P.O. Box 29535, Raleigh, North Carolina 27626-0535 Telephone [phone] FAX [phone]
An Equal Opportunity Affirmative Action Employer ' 50% recycled/ 1 O% post -consumer paper

NOTES FOR THOMASVILLE FURNITURE
PERMIT RENEWAL (NC0023604)
Wastewater discharge from Thomasville Furniture Industries, Inc. (Thomasville,
Davidson County) to a UT to Flat Swamp Creek in the Yadkin -Pee Dee River
Basin.
15A NCAC 2B .0300 Index #: Flat Swamp Cr classified as C (#12-123) in 7/1/73.
ATC Information:
• 12/1/95 ATC issued for recirculating sandfilter, flow splitter, recirculation tank
with air diffuser, filter screens/dual pumps, and tablet chlor/dechlor. The
polishing pond would be removed from service.
Basinwide Plan Information:
• This sub -basin (03-07-04) has seen effects from some point sources on stream biota;
severe effects ourban runoff have been seen in poor bioclassifications assigned to
Grants Cr and Town Cr during studies in 1990 (each listed on the 303(d) list) .
• Chemical samples from ambient sites indicate that most streams are very turbid,
but low DO is rarely a problem. Point source dischargers and urban runoff lead to
high conductivity levels in Salem Cr, Muddy Cr, Grants Cr, Abbotts Cr, and
Crane Cr. Many of these streams also have high concentrations of nitrogen and
phosphorus, but long-term data indicate these have been reduced by improved
wastewater treatment.
• There are no ambient monitoring stations near this discharge.
• Most streams in agricultural areas were assigned a good -Fair rating, often with a
severely degraded habitat.. The normal rocky riffle areas of piedmont streams were
reduced or entirely eliminated by massive inputs of coarse sand, reducing the
available habitat for benthic macroinvertebrate and fish.
• Ambient monitoring indicates that most streams in this area are very turbid, but
low DO is rarely a problem. Plan contains no specific recommendations for the
vicinity of this discharge.
Correspondence:
• Pursuant to permit requirement, EAA was submitted on 2/14/95, and upon
review, DWQ concurred that upgrading the existing plant was the best alternative
via letter on 7/7/95.
• 8/21/95 letter denied an extension of the deadline for compliance with a non -
discharge alternative, since an ATC had not been issued.
• SOC issued 6/17/96.
• 3 NOVs for ammonia, 2 NOVs for BOD5/TSS, and 1 fecal in '96.
• 11/6/96 Compliance inspection report noted these violations, among others;
however, it also noted that no violations were noted for the previous 3 months,
coinciding with the installation of tertiary sand filters (as required by SOC that
expired 11/1/96).
• 2 NOVs for ammonia in '97. 1 NOV for ammonia issued in '98.
• 1/7/98 letter from WSRO responded to a request from the facility to place the
polishing pond back into service to aid in nitrification/denitrification. Letter
stated that no violations, had occurred since 3/97, since supplemental organic
matter (dog food) was being added to the plant— the average flow had been only
600 gpd (well under design of 12,500 gpdand so organic matter was seriously

NC0023604
BAB
lacking. RO asserted that because data was trending towards consistent
compliance, it was hesitant to endorse a large process change, but would allow
pond temporarily to be put into service on a trial basis.
'97-'98 DMR Review:
• Flows average 600 gpd. Temps. and pH data fine. TRC below detect (0.015 mg/1),
and fecal normally < 1/100 ml. TSS < 5.0 mg/1.
• Effluent DOs around 7-9.5 mg/1, depending on season. BOD5 normally < 3 mg/1
(often < 1.00).
• Ammonia higher in early '97 (as high as 9-12 in 1/97), but then usually <0.5 mg/1
the remainder of the year. Appeared to begin same trend in '98, but fell < 1 mg/1
the rest of the year.
• Instream data: No trend in conductivity, temperature, or fecal. Several instances
of no flow. DO measurements are the same or slightly higher downstream than
those upstream. Some.levels were recorded below the standard (4-5 mg/1) during
summer low flow conditions.
General Comments:
Facility wishes to add dry kiln condensate discharge to the permit (a separate
discharge point, 002?) of 30 gpd. Per a conversation with Miki Ford of the
company (2/9/99), the company stores green lumber in a yard to air dry, and then
processes the lumber through large kilns (a big garage -like heater). Steam is fed
through the coils and never comes in contact with the lumber. The application,
however, says "water released from lumber in kiln drying, process"... this is
important because if condensate is coming from lumber, it might be considered
oxygen -consuming waste, and would not be allowed (zero flow stream) . If
condensate is from steam inside coils and never contacts lumber, 02-consuming not
an issue.
Jennifer Frye at the WSRO inspected the facility on 1/12/99, and the polishing
pond had not yet been put back into service (construction was underway to put it
back into the treatment loop); it is now operating.
Per Steve Pellei's 12/7/98 Memo regarding nutrient monitoring in the Yadkin
basin, this facility should be given quarterly TN and TP monitoring.
Facility submitted individual renewal application per my request. From a water
balance, the facility has now determined that dry kiln condensate discharge will be
17,433 gpd! This is a significant amount of water— where is the condensate going
currently?? I spoke with Jimmy Wilson, the Environmental Coordinator at the
plant on 3/1/99, who explained the situation: he had always reported discharge of
the condensate on permit applications, but the outfall was never included for some
reason; condensate has been discharged for years. The discharge is condensate
buildup in the steam coils (water never contacts lumber), and this small amount is
discharged through the stormwater outfall SW-2, as indicated on the map sent with
the general permit application. Discharge is intermittent and definitely no more
than 30 gpd. Water balance may not have considered runoff to
pond/evaporation... ? Flow at 002 need not be limited.
NH3 limits changed to 2/4; no record that 1/1.8 result of 02-consuming restraints.
Expiration date to be assigned to this permit is May 31, 2004.
page 2

A. Preston Howard, Jr., P.E.
NCDENR, Division of Water Quality
P.O. Box 29535
Raleigh, NC 27626-0535
Subject:
Dear Mr. Howard:
November 30, 1998
Certified Mail # Z 254 294 304
Renewal of NPDES Permit No. NC0023604
Thomasville Furniture Industries, Inc.
Plant SFD
Davidson County
In accordance with our permit, I hereby request renewal of the NPDES Permit for the
above referenced facility. This permit is scheduled to expire on May 31, 1999. If you
have any questions, please call me at [phone].
Sincerely,
J,(r
Miki Ford
Environmental Services
cc: Rochelle Chisom, Eng.
Larry Belton, Eng.
Jimmy Wilson, SFD
Tim Holliday, SFD
Dave Masters, 2nd floor
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Thomasville Furniture Industries, Inc. • P.O. Box 339 • Thomasville, North Carolina 27361-0339 • 910.472.4000