NC0023604_Wasteload Allocation_19930602

NPDES DOCUMENT SCANNINO COVER SHEET
NC0023604
NPDES Permit:
Document Type:
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:
June 2, 1993
Thies document is printed on reuse paper - ignore any
content on the rewerae aide

100% DOMESTIC FACILITIES - RECD 4/93
RENEWING WITHOUT MODIFICATION
BY MODELER
Permit # Facility
Stream
FINAL LIST
Sub -basin County
Request
Region WLA? MOD ENG Comments
SAW.
06/02/93
71781 HOOD ROAD SUBDIVISION
41556 FAIR GROVE ELEMENTARY SCHOOL
41629 DAVIS-TOWNSEND ELEM SCHOOL
42145 MIDWAY ELEMENTARY SCHOOL
75078 WILKES COUNTY AIRPORT
49689 PLEASANT GROVE TRAILER PARK
72664 SHUFORD MILLS, INC.
23604 THOMASVILLE FURNITURE
REEDY CREEK
UT HAMBY CREEK
UT HAMBY CREEK
LEONARD CREEK
UT YADKIN RIVER
UT HUNTS FORK CREEK
THIRD CREEK
UT FLAT SWAMP CREEK
KEYS TO COMMENTS:
0a. No policy given. Alternatives analysis should be required.
0b. Facility must meet 5 & 1 (by date given in parenthesis).
0c. Alternatives analysis requested.
0d. Alternatives analysis submitted.
0e. Facility will connect to POTW.
1. Phased permit.
2. Documented instream water quality problems.
3. Facility is requesting modification.
4. WLA should be done per basinwide permitting schedule.
030711
030707
030707
030707
030701
030707
030706
030704
MECKLENBURG
DAVIDSON
DAVIDSON
DAVIDSON
WILKES
DAVIDSON
ALEXANDER
DAVIDSON
MRO
WSRO
WSRO
WSRO
WSRO
WSRO
MRO
WSRO
SAW CA
SAW JS 0a
SAW JS Oa
X SAW JS Phased permit to zero -flow stream (4).
SAW JS wla not found
SAW SG Ob (3/31/95)
SAW SR
SAW SR 0b (8/1/95)
NOTE: IF 'X' UNDER "Request WLA?" COLUMN,
THE ENGINEER SHOULD REQUEST A WASTELOAD ALLOCATION.
ALSO, FOR A 'Oa' COMMENT, GIVE CURRENT ZERO -FLOW POLICY.
FOR A'Ob' COMMENT, GIVE 5 & 1 LIMITS BY DATE IN PARENTHESIS.

NPDES WASTE LOAD ALLOCATION
PERMIT NO.: NC0023604
PERMIITEE NAME: Thomasville Furniture Industries, Inc.
FACILITY NAME: SFD/64 Lumber Plant
Facility Status: Existing
Permit Status: Renewal
Major Minor
Pipe No.: 001
Design Capacity: 0.0125 MGD
Domestic (% of Flow): 95 %
Industrial (% of Flow): 5* %
Comments:
* See schematic: boiler blowdown enters final stage - polishing pond.
STREAM INDEX: 12-123
RECEIVING STREAM: an unnamed tributary to Flat Swamp Creek
Class: C
Sub -Basin: 03-07-04
Reference USGS Quad: D18SE, Fair Grove
County: Davidson
Regional Office: Winston-Salem Regional Office
Previous Exp. Date: 6/30/92 Treatment Plant Class: II
Classification changes within three miles:
ca. 10 mi. to High Rock Lake
Requested by:
(please attach)
Jule Shanklin 1' Date: 2/14/92
Prepared by: �i � .. 1 _ :.., Date: 3 'i I ' z
Reviewed by: l .Cl� 0)m d14 /d-P-Y"? Date: a'
34'.5 (qv.) (R) j 12 /23.1 ('fw) LB
GwLIEL
q 2--
Modeler
Date Rec.
#
SA -to
Z'\-1 L
ta'1't O
Drainage Area (mi2) j. 41 Avg. Streamflow (cfs): ( .
7Q10 (cfs) fl Winter 7Q10 (cfs) p 30Q2 (cfs)
0
Toxicity Limits: IWC % Acute/Chronic
Instream Monitoring:
Parameters -I). O., lerAPEBATi r�-cR t. Co t< I Go N'PttCfr v i Ty
Upstream 5 Location AT 1. ft ST (oouvsrgz6:146%
Downstream y
Location Pr UAW 300' pown)s-r126-Arvt
(5 vl le5 a6e Y g5
Effluent
Characteristics
A
Sumito 14
S
Sum/wit.,
5 /to
BOD5 (mg/1)
it /t 1
NH3-N (mg/1)
4 /4
1 %l.B
D.O. (mg/1)
6 /6,
to /',
TSS (mg/1)
300
30/30
F. Col. (/100 ml)
200/2o
zoo/aoa
pH(SU)
6,^1
6-1
gc-41DuAl. CALORlNE (
4)
1 1
foAremati3O (c c) :
NOT To Eiccee D Z.
g °C ABoVE it A7uRA
W14TER -rENttWERRATUJ2E
Exce&D 32°c
AND 1 a No C ii
pLoTTED
Comments: VIse44A(14E IS TV A 7 o ROW STTt MM. YEcon-M iP PFMovA t..
of IDISCfAC246. FACILITY Aw.si sUP4v ur Fn141niceiztN4 RePoOT viral1/J 12 nmus
SitoWI1•14 ofirci lktrut'E ItiDKGHRRe,E. fAut.tTV WILL REGE9J6 EXt5TIN4
L&MITS Fo2764E ROT -OWE %/EAR_S AND MOPE 9T12I1k4ENr L(MIT'S APT f?
Tr{adls ' f Arbs .

Alt pZ121933oS`87
NGooL3(x0f
/NaMASv/LLE /tco,t /S FDAit zz9m6
kr Fcfir 57A) (1g ,
14 117oA: /5%( &en 1t�7•1,1)
5FP/64- Lun+8Tria-
1Q�vi' D,O r(s f
092=o.0 k,—
L,9
r
5,
( (467N j- _L/Ml tS %
N/43-N= 4/
%SS = 30/3 p
Do/009
ONLY N E CLAU 9 re s it FIDPIPown/ Cooz,/. J j4
WA5 /NS£eT&D /Nro T//5 ourFFlGL -NV SfCC/AL L/f(75)
S &' 17s d'° L / TloN S , f rLCAL COLT , f Po 0,91_,4 T/v N
. �ECan N. �i 2 •a .2 FLo W_ CY
FRcaL-/TY NA9 e'7F,N 0 A4e47-10/J 44( 4' - p4,647 Drd/J/ mg+ pd4M4�
fiLla JT /?A%!7 S /L.EL 4°' To .b /5/IINC Por)v rd/Tip/ PA
/4i%GN!(ON 7774r;
/NSi i 7/1, 1)j174
SFlow'La LcSy NA -A,/ S uP 5. POwAI502-ZA-nt,
D.O. s ?4-.5. LAW
AS l • I D0 01/62 5 r ( �� /!V
7 l o use ' (i Yt&tveo.vvt. %.cwt V pek1) 6 447,

Facility Name:
NPDES No.:
Type of Waste:
Facility Status:
Permit Status:
Receiving Stream:
Stream Classification:
Subbasin:
County:
Regional Office:
Requestor:
Date of Request:
Topo Quad:
FACT SHEET FOR WASTELOAD ALLOCATION
Request # 6770
SDF/64 Lumber (Thomasville Furniture)
NC0023604
95% Dom/ 5% Ind
Existing
Renewal
UT Flat Swamp Creek
C
030704
Davidson
WSRO
J. Shanklin
2/14/92
D18SE
Stream Characteristic:
USGS #
Date:
Drainage Area (mi2):
Summer 7Q10 (cfs):
Winter 7Q10 (cfs):
Average Flow (cfs):
30Q2 (cfs):
IWC (%):
RECEIVED
N.C. Dept. of EHNR
MAR 2 4 19921
Winston-Salem
Regional Office
1.49
0.0
0.0
1.4
0.0
100.0
Wasteload Allocation Summary
(approach taken, correspondence with region, EPA, etc.)
Facility discharges to stream with 7Q10/30Q2 = O. Removal of discharge is recommended in
three years or new limits (page 2) will apply at that time. Facility must submit an engineering
report within 12 months of the effective date of this permit showing no alternative to surface water
discharge.
This discharge includes boiler blowdown. The previous permit had no special limit requirements
regarding this (just the standard language for cooling H20). Domestic and blowdown goes to a
polishing pond with 54 day retention time. The facility has had 3 BOD5, 1 Fecal coli, and 1 DO
violation in the past year. Instream DO's were less than 5 mg/1 up and downstream, with values as
low as 1.1 mg/l. — ---
Special Schedule Requirements and additional comments from Reviewers:
Recommended by:
Reviewed by
Instream Assessment: AA-6A- !'..1"ti-tA6F7Y‘-
Date:
Date:
Regional Supervisor:ga4Mtia-
• C..�-��-- Date: 3- 2 6 —5
Permits & Engineering: Date: 5I 3°/91-'
RETURN TO TECHNICAL SERVICES BY:
APR i 8 1992
1-

Existing Limits:
Wasteflow (MGD):
BOD5 (mg/1):
NH3N (mg/1):
DO (mg/1):
TSS (mg/1):
Fecal Col. (/100 ml):
pH (SU):
Residual Chlorine (4/1):
Oil & Grease (mg/1):
TP (mg/1):
TN (mg/1):
Recommended Limits:
Wasteflow (MGD):
BOD5 (mg/1):
NH3N (mg/1):
DO (mg/1):
TSS (mg/1):
Fecal Col. (/100 ml):
pH (SU):
Residual Chlorine (14/1):
Teyv',rn�c v �e C° c,
2
PARAMETERS
Monthly Average
Summer Winter
0.0125 0.0125
11 11
4 4
6 6
30 30
1000 1000
6-9 6-9
For three years:
Monthly Average
Summer Winter
0.0125 0.0125
11 11
4 4
6 6
30 30
200 200
6-9 6-9
WQ or EL
After three years:
Monthly Average
WQ or EL Summer Winter WQ or EL
0.0125 0.0125
5.0 10.0
1.0 1.8
6.0
30.0
200.0
6.0 - 9.0
17.0
(04 -{1) exteed D.S°C. ckr2 0- rc-0
u.' ttn i e wtQ. vvti ►gyp CLG. eAcCeec) 3 a°C.
Limits Changes Due To: Parameter(s) Affected
Change in 7Q10 data
New regulations/standards
New procedures
New facility information
Change in stream classification
Other
Fecal coliform
BOD5, NH3-N, Cl
6.0
30.0
200.0
6.0 - 9.0
17.0
WQWWQ
WQ
WQ
WQ
WQ
_X Parameter(s) are water quality limited. For some parameters, the available load capacity of
the immediate receiving water will be consumed. This may affect future water quality based
effluent limitations for additional dischargers within this portion of the watershed.
OR
No parameters are water quality limited, but this discharge may affect future allocations.

3
INSTREAM MONITORING REQUIREMENTS
Upstream Location: at least 100 ft upstream
Downstream Location: at least 300 ft downstream
Parameters: DO, temperature, Fecal coliform, conductivity
Special instream monitoring locations or monitoring frequencies:
MISCELLANEOUS INFORMATION & SPECIAL CONDITIONS
Adequacy of Existing Treatment
Has the facility demonstra4 the ability to meet the proposed new limits with existing treatment
facilities? Yes No ✓✓
If no, which parameters cannot be met? ck3V,m-
Would a "phasing in" of the new limits be appropriate? Yes No V
If yes, please provide a schedule (and basis for that schedule) with the regional
office recommendations:
If no, why not?
.ti,2
`"-DCi`O.c\c.QC 0S Cvs) `
Special Instructions or Conditions
Wasteload sent to EPA? (Major) _N_ (Y or N)
(If yes, then attach schematic, toxics spreadsheet, copy of model, or, if not modeled, then old
assumptions that were made, and description of how it fits into basinwide plan)
Additional Information attached? _N (Y or N) If yes, explain with attachments.

cc:
Permits and Engineering
Technical Support Branch
County Health Dept.
Central Files
WSRO
SOC PRIORITY PROJECT: No X
MAR i 21993
1 ,!'F'~Jp j A 1CH
To: Permits and Engineering Unit
Water Quality Section
Attention: Susan Robson
Date: March 10, 1993
NPDES STAFF REPORT AND RECOMMENDATION
County Davidson
Permit No. NC0023604
PART I - GENERAL INFORMATION
1. Facility and Address: Thomasville Furniture Industries, Inc.
SFD/64 Lumber Plant
P. O. Box 339
Thomasville, N.C. 27361-0339
2. Date of Investigation: February 25, 1993
3. Report Prepared by: Mike Mickey, Environmental Tech V
4. Persons Contacted and Telephone Number: Mr. Dave Masters,
Mgr, Safety, Health & Security, ph [phone]
5. Directions to Site: Take Hwy 64 east out of Lexington. The
facility is located on the right side of the highway just
past New Cut Road (SR 2262).
6. Discharge Points(s), List for all discharge points:
Latitude: 35° 46' 30" Longitude: 80° 07' 12"
U.S.G.S. Quad No. D-18-SE U.S.G.S. Quad Name: Fair Grove
7. Site size and expansion area consistent with application ?
X Yes
8. Topography (relationship to flood plain included): The
plant site is relatively flat but above the flood plain. A
stream runs through the back of the property.
9. Location of nearest dwelling: No dwellings are located
within a 1000 ft of the discharge point.
10. Receiving stream or affected surface waters: U.T. to Flat
Swamp Creek.

a. Classification C
b. River Basin and Subbasin No.: YAD-04
c. Describe receiving stream features and pertinent
downstream uses: The WWTP discharges into a zero flow
stream behind the facility (7Q10 & 30Q2 = 0; DA = 1.49
sq. mile)
Part II - DESCRIPTION OF DISCHARGE AND TREATMENT WORKS
1. a. Volume of Wastewater to be permitted: 0.0125 MGD
(Ultimate Design Capacity) Self -monitoring data shows
an average flow of 0.0018 MGD for 1992.
b. What is the current permitted capacity of the Waste
Water Treatment facility? Same as above.
c. Actual treatment capacity of the current facility
(current design capacity)? Same as above.
d. Date(s) and construction activities allowed by previous
Authorizations to Construct issued in the previous two
years. NA
e. Please provide a description of existing or
substantially constructed wastewater treatment
facilities; The existing facility is a 0.0125 MGD
extended aeration package plant with sludge holding and
chlorination. The effluent from the package plant goes
into a fifty-four day polishing pond before being
discharged from the cascade aerator to the creek.
The boiler blowdown from the facility is routed around
the package plant and into the polishing pond. The
boiler water is then discharged with the domestic
wastewater through a common outfall.
f. Please provide a description of proposed wastewater
treatment facilities. NA
g•
Possible toxic impacts to surface waters: None known.
h. Pretreatment Program (POTWs only): NA
2. Residuals handling and utilization/disposal scheme:
a. Other disposal/utilization scheme: Septage Pumper
3. Treatment plant classification: Class II (40 points)
4. SIC Code(s): 2511 Primary: 02 Secondary: 16
Main Treatment Unit Code: 0 6 5 X 7
NPDES Permit Staff Report
Version 10/92
Page 2

PART III - OTHER PERTINENT INFORMATION
1. Is this facility being constructed with Construction Grant
Funds or are any public monies involved. (municipals only)?
NA
2. Special monitoring or limitations (including toxicity)
requests: None
3. Important SOC, JOC or Compliance Schedule dates: (Please
indicate) NA
4. Alternative Analysis Evaluation: Thomasville Furniture
(TFI) submitted an engineering study evaluating wastewater
disposal alternatives to DEM on 1-29-93 as required by Part
III (E) of their current permit. The findings are as
follows:
Spray Irrigation: A soils evaluation found that marginal
soil exists for the installation of a spray irrigation
system on twelve acres of TFI land. The costs are estimated
at $162,400.
Connection to Regional Sewer System: Two possibilities
exist for TFI to connect to Lexington's sewer system. The
first would involve 4.1 miles of a pump station and force
main system to Hwy's 64 and 85 at a cost of $225,000. The
second option would involve 1.8 miles of a P.S.F.M. if a
proposed elementary school is relocated near TFI. The
feasibility of this option will not be known until 1994.
The estimated cost would be $145,100.
Subsurface: A soils evaluation found that marginal soil
exists on the TFI site for the installation of a LPP system
on 5.7 acres (including repair area). The costs are
estimated at $154,000.
Other disposal options: The study also evaluated the option
of continuing to discharge at the existing location and
upgrading the WWTP to meet 5mg/1 BOD and lmg/1 NH3N. This
was determined to be the least environmentally sound
alternative with a cost of $165,700.
5. Other Special Items: None.
PART IV - EVALUATION AND RECOMMENDATIONS
The Thomasville Furniture Lumber plant has approximately 100
employees and manufactures parts for wood furniture. The package
plant only receives domestic wastewater. The effluent from the
NPDES Permit Staff Report
Version 10/92
Page 3

package plant and the boiler are routed into a 54 day polishing
pond before being discharged through a common outfall to the U.T.
which is a "zero flow" stream.
A review of the self -monitoring data shows that the facility
was compliant with all final limits in 1992 except for one TSS
Violation in March (Probably due to algae from the polishing
pond). It is relevant to note that the system does not discharge
every month since wastewater can be held in the polishing pond
for extended periods of time.
In addition to the engineering study, Part III (E) of their
present permit also stated that the final limits are scheduled to
change to 5 mg/1 BOD and 1 mg/1 NH3-N effective 8-1-95. This
date should remain in the next permit even though monitoring data
indicates that the system cannot meet the proposed new limits.
The engineering report was received on 1-29-93 and concluded
that "all three non -discharge alternatives are environmentally
feasible." The report also stated that "that relocation of the
discharge to a positive flowing stream was not environmentally
feasible." Therefore, WSRO recommends reissuance of the permit
with the following compliance schedule:
1) Submit complete plans and specifications to DEM for
either a sewer line extension permit or a nondischarge
permit on or before June 1, 1994.
2) Begin construction of the WWTP improvements in
accordance with the approved plans by April 1, 1995.
3) Complete construction in accordance with the plans by
August 1, 1995. (This coincides with the date that the
limits change to 5 and 1).
VAJVN - - \\ • �3
Signature of report prepar Date
Water Quality Regioliial Supervisor
NPDES Permit Staff Report
Version 10/92
Date
Page 4

State of North Carolina
Department of EnvironYnent, Health, and Natural Resources
Winston-Salem Regional Office
James B. Hunt, Jr., Governor
Jonathan B. Howes, Secretary
DIVISION OF ENVIRONMENTAL MANAGEMENT
Water Quality Section
March 8, 1993
Mr. David R. Masters
Thomasville Furniture Industries, Inc.
P. O. Box 339
Thomasville, N.C. 27361-0339
SUBJECT: Engineering Study
SFD/64 Lumber Plant
NPDES Permit No. NC0023604
Davidson County
Dear Mr. Masters:
This letter is to acknowledge receipt of the engineering
study prepared by ESE Biosciencies, Inc., for the Thomasville
Furniture SFD/64 Lumber Plant. The engineering study was
required by Part III (E) of the above permit due to the zero 7Q10
flow and the potential for ammonia toxicity in the receiving
stream.
A review of the report indicates that the information is
thorough and complete. Our office is in agreement with the
report's conclusion that continuing to discharge at the existing
location is the least environmentally sound alternative once the
limits become more restrictive. Therefore, Thomasville Furniture
should proceed with the necessary planning and funding in order
to implement one of the three non -discharge alternatives outlined
in the report.
As you are aware, the NPDES permit is presently up for
renewal. The new permit will contain a specific timetable
requiring Thomasville Furniture to implement the findings of the
study. It is expected that the permit will require the
elimination of the discharge from the SFD/64 Lumber Plant on or
before August 1, 1995. This is the date that the 5 mg/1 BOD and
1 mg/1 NH3-N limits are scheduled to become effective.
8025 North Point Boulevard, Suite 100, Winston-Salem, NC 27106-3203 • Telephone [phone] • FAX [phone]
An Equal Opportunity Affirmative Action Employer

Mr. David R. Masters
March 8, 1993
Page #2
You will receive a draft copy of the permit in about two
months. Please review the proposed compliance schedule carefully
to see if the dates are feasible. Should you have any questions,
please do not hesitate to contact Mr. Mike Mickey or me at (919)
896-7007.
Sincerely,
M. Steven Mauney
Water Quality Supervisor
cc: Collen Sullins
ESE Biosciences, Inc.
Central Files
WSRO