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Home My WebLink AboutNC0000639_Permit (Issuance)_20061011NPDES DOCIMENT SCANNING COVER SHEET NC0000639 Sapona Manufacturing Company NPDES Permit: Document Type: Permit Issuance Wasteload Allocation Authorization to Construct (AtC) Permit Modification Complete File - Historical Engineering Alternatives (EAA) Correspondence Instream Assessment (67b) Speculative Limits Environmental Assessment (EA) Permit History Document Date: October 11, 2006 This document is printed on reuse paper - ignore any content on the reYerse side Michael F. Easley, Governor William G. Ross Jr., Secretary North Carolina Department of Environment and Natural Resources Alan W. Klimek, P.E. Director Division of Water Quality October 11, 2006 Mr. Dean F. Lail Sapona Manufacturing Company, Inc. 2478 Cedar Falls Road Cedar Falls, North Carolina 27230 Subject: Issuance of NPDES Permit NC0000639 Sapona Manufacturing Company Randolph County Dear Mr. Lail: 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). This final permit includes the following major changes from the draft permit sent to you on August 30, 2006: > To support nutrient -sensitive modeling for the Deep River watershed, quarterly nutrient monitoring has been added to outfall 001. A summary of the Division's nutrient monitoring strategy is enclosed for your reference. > A re -opener condition has been added in the event that a different nutrient monitoring regimen becomes necessary later in the permit cycle. 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 legal requirements to obtain other permits which may be required by the Division of Water Quality or permits required by the Division of Land Resources, 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 Charles Weaver at telephone number (919) 733-5083, extension 511. Sincerely, s Alan W. Klimek, P.E. cc: Central Files Winston-Salem Regional Office/Surface Water Protection NPDES Unit No `Carolina ,Naturally North Carolina Division of Water Quality 1617 Mail Service Center Raleigh, NC 27699-1617 Phone (919) 733-5083 Customer Service Internet h2o.enr.state.nc.us 512 N. Salisbury St. Raleigh, NC 27604 FAX (919) 733-0719 1-877-623-6748 An Equal Opportunity/Affirmative Action Employer-50% Recycled/10% Post Consumer Paper Permit NC0000639 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, Sapona Manufacturing Company, Inc. is hereby authorized to discharge wastewater from a facility located at Sapona Manufacturing Company 2478 Cedar Falls Cedar Falls Randolph County to receiving waters designated as the Deep River in the Cape Fear 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 November 1, 2006. This permit and authorization to discharge shall expire at midnight on September 30, 2011. Signed this day October 11, 2006. cs Alan W. Klimek, P.E., Director Division of Water Quality By Authority of the Environmental Management Commission Permit NC0000639 SUPPLEMENT TO PERMIT COVER SHEET All previous NPDES Permits issued to this facility, whether for operation or discharge are hereby revoked. As of this permit issuance, any previously issued permit bearing this number is no longer effective. Therefore, the exclusive authority to operate and discharge from this facility arises under the permit conditions, requirements, terms, and provisions included herein. Sapona Manufacturing Company, Inc., is hereby authorized to: 1. Continue operation of a 0.01 MGD wastewater treatment facility with the following components: ❖ Manual bar screen ❖ Aeration basin with diffused aeration from 2 blowers ❖ Clarifier with sludge return + Effluent chlorination This system discharges via outfall 001 from a facility located at 2478 Cedar Falls Road in Cedar Falls, Randolph County. 2. Continue to discharge boiler blowdown, cooling tower blowdown, and air washer wastewater via outfall 002. 3. Discharge from said treatment works at the locations specified on the attached map into the Deep River, classified C waters in the Cape Fear River Basin. ,USGS Quad No. x1USGS Quad Name Quad: Ramseur, N.C. Latitude: 35°44'51"(001); 35°44'50" (002) Longitude: 79°43'33" (001); 78°43'34" (002) Stream Class: C Subbasin: 30609 Receiving Stream: Deep River NC0000639 Sapona Manufacturing Company North SCALE 1:24000 Permit NC0000639 A. (1.) EFFLUENT LIMITATIONS AND MONITORING REQUIREMENTS (001) During the period beginning on November 1, 2006 and lasting until expiration, the Permittee is authorized to discharge from outfall 001 (Domestic Waste). Such discharges shall be limited and monitored by the Permittee as specified below: PARAMETER : DISCHARGE LIMITATIONS ; MONITORING REQUIREMENTS.... Monthly Average -Daily Maximum Measurement Frequency Sample ° Type Sample Location Flow 0.01 MGD Weekly Instantaneous Influent or Effluent BOD, 5-day, 200C 30.0 mg/L 45.0 mg/L Weekly Grab Effluent Total Suspended Solids 30.0 mg/L 45.0 mg/L Weekly Grab Effluent NH3-N 2/Month Grab Effluent Fecal Coliform (geometric mean) 200 / 100 ml 400 / 100 mi Weekly Grab Effluent Total Residual Chlorines _ 28 pg/L 2/Week Grab Effluent Temperature Weekly Grab Effluent Total Nitrogen (NO2 + NO3 + TKN) • Quarterly Grab Effluent Total Phosphorus Quarterly Grab Effluent pH > 6.0 and < 9.0 standard units 2/Month Grab Effluent NOTES: 1. The TRC limit takes effect May 1., 2008. Until then, the permittee shall monitor TRC [with no effluent limit]. THERE SHALL BE NO DISCHARGE OF FLOATING SOLIDS OR VISIBLE FOAM IN OTHER THAN TRACE AMOUNTS. A. (2.) EFFLUENT LIMITATIONS AND MONITORING REQUIREMENTS (002) During the period beginning on the effective date of the permit and lasting until expiration, the Permittee is authorized to discharge from outfall 002 (Boiler Blowdown, Cooling Tower Blowdown, Air Wash Wastewater). Such discharges shall be limited and monitored by the Permittee as specified below: PARAMETER DISCHARGE : LIMITATIONS MONITORING REQUIREMENTS Monthly Average Dail Maximum . Measurement `: Frequency ': Sample Type Sample Location Flow (MGD) Semi-annually Estimate Effluent Temperature1 Semi-annually Grab Effluent Total Residual Chlorine2 28 pg/L Semi-annually Grab Effluent pH ! > 6.0 and < 9.0 standard units 1 Semi-annually Grab Effluent NOTES: 1. The temperature of the effluent shall be such as not to cause an increase in the temperature of the receiving waters of more than 2.8°C and in no case cause the ambient water temperature to exceed 32°C. 2. The TRC limit takes effect May 1., 2008. Until then, the permittee shall monitor TRC [with no effluent limit]. This monitoring requirement only applies if chlorine is added to the cooling water. THERE SHALL BE NO DISCHARGE OF FLOATING SOLIDS OR VISIBLE FOAM IN OTHER THAN TRACE AMOUNTS. Permit NC0000639 . A. (3.) BIOCIDE CONDITION There shall be no chromium. zinc or copper added to the treatment system except as pre -approved additives to biocidal compounds. The permittee shall obtain approval from the Division's Aquatic Toxicology Unit prior to the use of any biocide (not previously approved by the Division) in the effluent discharged under this permit. Approval for use of any biocide not previously approved should be requested at least 90 days in advance of any planned usage. Contact the Aquatic Toxicology Unit for detailed instructions on requesting approval of biocides: NC DENR / DWQ / Aquatic Toxicology Unit 1621 Mail Service Center Raleigh, North Carolina 27699-1621 Concentrations of chromium, copper, or zinc added to biocides shall not exceed applicable water quality standards or action levels in the receiving stream. A. (4.) PERMIT RE -OPENER: SUPPLEMENTARY MONITORING The Division may, upon written notification to the Permittee, require additional effluent monitoring that it deems necessary to support its water quality protection and restoration efforts in the receiving stream. NORTH CAROLINA RANDOLPH COUNTY AFFIDAVIT OF PUBLICATION Before the undersigned, a Notary Public of said County and State, duly commissioned, qualified, and authorized by law to administer oaths, personally appeared Maria Shaw who being first duly sworn, deposes and says, that he (she) is Business Manager Of The Courier -Tribune, engaged in the publication of a newspaper known as The Courier -Tribune, published, issued, and entered as second class mail in the City of Asheboro, in said County and State; and the he (she) is authorized to make this affidavit and sworn statement; that the notice or other legal advertisement, a true copy of which is attached hereto, was published in the Courier - Tribune on the following dates: September 1, 2006 and that the said newspaper in which such notice, paper, document, or legal advertisement was published was, at the time of each and every such publication, a newpaper meeting all of the requirements and qualifications of Section 1-597 of the General Statutes of North Carolina, 1943, as amended, and was a qualified newspaper within the meaning of Section 1-597 of the General Statutes of North Carolina. this 1st day of September, 2006 Sworn to and subscribed before me this 1st day o•r.September, 2006 Notary Public My commission expires: 6/19/11 I, -'PUBLIC NOTICE' STATE ORNoRn'jji CroROUNA;, :...ENVIRONMENTAL VIIIANAGE= mENT COMMiSSIONIN PDES `UNIT 1617 MAiL'SERVICE-> '.17;1 CEintAR ALEIGH NC.' ''27699-1¢1.7 it , ^ NOTIFlCATION.OPINTENT. 'I TO.ISSUEANPRES,WASTE-':.:1 • ` WATE PERRMIT�•w , I x, '�3. n ;Or! thheb` stof.' hofough`staff' ,ravfeW`If-'filrr:' ciff.Ve NC " ;General Stet 2f;.public Law, 92-5t)d:and:'esther lawful • istahaii0 9iiid,, egtilatio : the ,.North,Car t)na,ppvireamerltal ManagertiontComrfs1s-sign dpro- l;poses: a-Nai on ouut- ant or igo Ellrttid'Sys= to ttNpD Es)'wi Sfewater dis. t . .c(iars@` a11��&ttghs persori(s),.�•: Elated beloi eifecttvs 'd5:da)rs; ({gr 't upli p date` of tt s no= rice w written.,00mroOts;Tegarding the, propoaodr permfl'trftrl rbe cepted unt 1.s 3Qda s • erthe • , pubilsh dale oiftht'ntce:'Atl ' ,coR4 ; t' nor. to.,ttrat: .date.are:consi the final ode orrnIr aUons egarding`.the l i : Director of a NC Water O is ty 1•> ;de a to holcta•apublic7: m« iig -Proposed Pe ►Rft' shdill l orAt klsigrsf cdlys.a :: Copies Witte"? t 'permit and 016 othe, ed, 7dgtor !to .Oonditions p es9R), , t e ,¢ a perSrift.are, e `_ aay- . E ion�ri• � I, �iS` g uC-'-r. qu !tor •Una .on -So tfre.lVC- Division .of Water Quality at the above: address or call the Paint Sottn 1 5083„ exten _ {i5Q , Pieces"` Inc._ elude' 1' P ES: a t' bam ber` atfaced) h ' y°com nuns , tion tntofilsted*ersorta may alsof�iits oDIvTslon of,Nater", • DtialFfyr51'2 NalSallsbury f r'street al tgh between e'hours'bf+6am •arid''* b r.34143 formatron - ,sapgq114, 9 CAms� `pang `Incr:(PO' ox'128; Cedar: Falls; NC.l» ,i ) applied' 1O is renewal of: ermt NCOd0O639 fora �,r�. s`iio County. , Is; permtt•facillty`d s. - chargea`�{eatdd wastewater to:`� : the Pg.9t ion tho.Cape Fear.: F1iv�r Basin urfentIy ; eca1 ooti=. Corm •andtbtal resldualchiortge' are water. J 'at( tirnited, This . - ) %/30/oh SAP O NA MANUFACTURING COMPANY, INC. Quality Yarns Since 1836 1/26/06 Ms. Valery Stephens NC DENR / Water Quality / Point Source Branch 1617 Mail Service Center Raleigh, NC 27699-1617 Re: Cover Letter for renewal of NPDES Permit NC0000639 Dear Ms. Stephens: Please renew our permit for wastewater discharge. The application is enclosed. There have been no significant changes to our system since issuance of the last permit. Please note that we have contracted with a company to manage our system. The company is Meritech Inc., 642 Tamco Rd. Reidsville, NC 27320. The ORC is Arnold Allred. Thank you, Dean F. Lail V. President Sapona Manufacturing Company, Inc. F �3 1 0 2006 Email: DLail@saponamfg.com Web: www.saponamfg.com P.O. Box 128 • 2478 Cedar Falls Road • Cedar Falls, NC 27230 • Ph. 336-625-2727 • Fax 336-626-0876 NPDES APPLICATION FOR PERMIT RENEWAL - FORM A For Publicly Owned Treatment Works (POW) or other treatment systems treating domestic wastes < 0.1 MGD with no pretreatment program. ,. Mail the complete application to: N. C. Department of Environment and Natural Resources Division of Water Quality / NPDES Unit 1617 Mail Service Center, Raleigh, NC 27699-1617 NPDES Permit INC0000639 F E B 1 0 2006 If you are completing this form in computer use the TAB key or the up - down arrows to move from one field to the next To check the boxes, click your mouse on top of the box. Otherwise, please print or type. ----_� 1. Contact Information: Owner Name Facility Name Mailing Address City State / Zip Code Telephone Number Fax Number e-mail Address Sapona Manufacturing Company, Inc. Sapona Manufacturing Company, Inc. r0 Box 128 Cedar Falls North Carolina 27230 (336) 625-2727 (336) 626-0876 lail@aol.com 1. Location of facility producing discharge: Check here if same address as above EJ Street Address or State Road 2478 Cedar Falls Road City State / Zip Code County Cedar Falls North Caret i na 27230 Randolph 1. Operator Information: Name of the firm, public organization or other entity that operates the facility. (Note that this is not referring to the Operator in Responsible Charge or ORC) Name Meritech, Inc. Mailing Address PO Box 27 City Reidsville State / Zip Code NC Telephone Number (336)342-4748 Fax Number (336)342-1522 4. Population served: 214 1 of 3 FomrA 4/05 NPDES APPLICATION FOR PERMIT RENEWAL - FORM A For Publicly Owned Treatment Works (POTW) or other treatment systems treating domestic wastes < 0.1 MGD with no pretreatment program. 9. Do you receive industrial waste? I No ❑ Yes (if you have an approved pre-treatment program, must complete Form 2A) 4. Type of collection system ® Separate (sanitary sewer only) ❑ Combined (storm sewer and sanitary sewer) 4. Outfall Information: Number of separate discharge points 2 Outfall Identification number(s) 001.002 Is the outfall equipped with a diffuser? ❑ Yes ® No 8. Name of receiving stream(s) (Provide a map showing the exact location of each outfall): Deep River 8. Frequency of Discharge: ® Continuous ❑ Intermittent If intermittent: Days per week discharge occurs: Duration: 8. Describe the treatment system List all installed components, including capacities, provide design removal for BOD, TSS, nitrogen and phosphorus. If the space provided is not sufficient, attach the description of the treatment system in a separate sheet of paper. A Package Plant Consisting of one Manual Barscreen, One Aeration Basin with Diffused Air from 2 Blowers, one Clarifier , V notch Weir for Manual Flow measurement, one Chlorine Contact Chamber with Hypochlorite addition for disinvection 8. Flow Information: Treatment Plant Design flow .01 MGD Annual Average daily flow .002 MGD (for the previous 3 years) Maximum daily flow .002 MGD (for the previous 3 years) 12. Is this facility located on Indian country? ❑ Yes ® No 2 of 3 Form -A 4/05 NPDES APPLICATION FOR PERMIT RENEWAL - FORM A For Publicly Owned Treatment Works (POTW) or other treatment systems treating domestic wastes < 0.1 MGD with no pretreatment program. 13. Effluent Data Provide data for the parameters listed. Fecal Conform, Temperature and pH shall be grab samples, for all other parameters 24-hour composite sampling shall be used. If more than one analysis is reported, report daily maximum and monthly average. If only one analysis is reported, report as daily maximum. Parameter Daily Maximum Monthly Average Units of Measurement Biochemical Oxygen Demand (BOD5) 8.6 2.5 mg/1 Fecal Coliform 1 <1 ml Total Suspended Solids 43 4.14 mg/1 Temperature (Summer) 28 15 C Temperature (Winter) pH 8.7 7.3 unit 13. List all permits, construction approvals and/or applications: Type Hazardous Waste (RCRA) NESHAPS (CAA) UIC (SDWA) Ocean Dumping (MPRSA) NPDES NC0000639 Dredge or fill (Section 404 or CWA) PSD (CAA) Other Non -attainment program (CAA) Permit Number 15. APPLICANT CERTIFICATION Type Permit Number I certify that I am fnmlliar with the information contained in the application and that to the best of my knowledge and belief such information is true, complete, and accurate. Deavk Lot; I Printed name of Person Signing Pre(CA evd- Title Signature of Applicant Date North Carolina General Statute 143-215.6 (b)(2) states: Any person who knowingly makes any false statement representation, or certification in any application, record, report, plan, or other document files or required to be maintained under Article 21 or regulations of the Environmental Management Commission implementing that Article, or who falsifies, tampers with, or knowly renders inaccurate any recording or monitoring device or method required to be operated or maintained under Article 21 or regulations of the Environmental Management Commission implementing that Article, shall be guilty of a misdemeanor punishable by a fine not to exceed $25,000, or by imprisonment not to exceed six months, or by both. (18 U.S.C. Section 1001 provides a punishment by a fine of not more than $25,000 or imprisonment not more than 5 years, or both, for a similar offense.) 3of3 Form-A4'05 FACT SHEET FOR EXPEDITED RENEMAL Permit Number NC J 0°0 (n 1 Facility Name V INAA Reviewer D (4- � Basin/Sub-basin 0 3 -- DUin/ (, ,�G ` - Receiving Stream -of Stream Classification in permit Stream Classification in BIMS 7 Is the stream impaired (listed on 303(d))? /.,10 Is stream monitoring required? ,\)�, Does the permit need NH3 limit(s)? 0 the permit need TRC limit(s)? YDoes �� iii Does the permit have toxicity testing? \, Are there special conditions? y c-> Any obvious compliance concerns? h,10 Existing Expiration Date 9 / 3 /b New Expiration Date c1/' O / / Miscellaneous Comments: If expedited, Is this a simper permit or a ore diffIcul ?one?