NC0041696_Permit Issuance_20010117

NPDES DOCUMENT SCANNING COVER MEET
NC0041696
Lake Rhodhiss WWTP
NPDES Permit:
Document Type:
Permit Issuance
Wasteload Allocation
Authorization to Construct (AtC)
Permit Modification
Complete File - Historical
Engineering Alternatives (EAA)
Report
Instream Assessment (67b)
Speculative Limits
Environmental Assessment (EA)
Document Date:
January 17, 2001
Thies document is printed on reuse paper - ignore any
cantent on the reirerse snide

State of North Carolina
Department of Environment
and Natural Resources
Division of Water Quality
Michael F. Easley, Governor
Sherri Evans -Stanton, Acting Secretary
Kerr T. Stevens, Director
January 17, 2001
Mr. Jeffrey V. Morse, Town Manager
Town of Valdese
P.O. Box 339
Valdese, North Carolina 28690-0339
Al�
I� CDENR
Subject: NPDES Permit Issuance
Permit No. NC0041696
Town of Valdese — Lake Rhodhiss WWTP
Burke County
Dear Mr. Morse:
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.) Several modifications were made to the permit during the draft phase:
• The addition of a one-year compliance schedule for the new mercury limit that will be placed in
your permit. The Town of Valdese will have twelve months of twice per month mercury
monitoring after which an effluent limitation of 0.25 ug/I will be effective at 7.5 MGD and a limit
of 0.18 ug/I at 10.5 MGD. After the twelve month compliance schedule, if Valdese has had twelve
consecutive months of mercury values below the detection level of 0.2 ug/1, then the Town may
submit a written request asking DWQ to re-evaluate the assignment of a mercury limit in the
NPDES permit.
• After further evaluation of the data used during our analysis, it was determined that sulfates limits
at 7.5 MGD and 10.5 MGD are no longer required. More recent data submitted by the Town was
more representative of the current treatment for this constituent. In addition, sulfates will be
monitored quarterly in the Town's Long Term Monitoring Plan (LTMP) and this data can be
evaluated upon next permit renewal.
• The chromium limit at 10.5 MGD will be deleted based on reevaluation of the submitted LTMP
data. Ten of the seventeen values of the chromium data were below detection and five values were
less than 13 ug/I. Based on further evaluation, it was determined that continued monitoring in the
LTMP would provide enough data for evaluation at the next permit renewal.
• After further evaluation of the data used during our analysis, it was determined that zinc
monitoring is no longer required. Continued monitoring in the LTMP would provide enough
data for evaluation at the next permit renewal.
1617 Mail Service Center, Raleigh, North Carolina 27699-1617 Telephone [phone]/FAX [phone]
An Equal Opportunity Affirmative Action Employer 50% recycled/ 10% post -consumer paper

• After further evaluation of the data used during our analysis, it was determined that zinc
monitoring is no longer required. Continued monitoring in the LTMP would provide enough data
for evaluation at the next permit renewal.
• The addition of monthly effluent monitoring for copper at 7.5 MGD and 10.5 MGD was based on
reasonable potential analysis of your pretreatment program's LTMP data.
• The results of the optimization study will be due by June 30, 2002 as requested by the Town. It is
required that the facility conduct Total Phosphorus (TP) optimization study on the plant as a result
of the elevated concentrations discharged in the effluent. The Division has concerns about the
increasing TP loading being exported into Lake Hickory. The optimization study should identify
the sources of TP loads and evaluate how to reduce and minimize these inputs to the plant. In
addition, the facility should review operational and treatment techniques to determine if TP
removal is being maximized.
• The monitoring frequency for NH3 has been corrected to weekly. The draft permit had the
monitoring frequency incorrectly given as twice per month.
• The monitoring frequency for phenols will be twice per month as given in the previous NPDES
permit.
The following modifications listed in the earlier draft will remain the same:
• The addition of an effluent page for wasteflow of 10.5 MGD based on facility's request for
expansion due to increased flow from local manufacturing company and future projected growth.
The Construction Grants and Loans Section has stipulated that the following areas must be
addressed and completed before the Valdese -Lake Rhodhiss WWTP can expand to 10.5 MGD.
There must be increased capacity and upgrading in the following:
1. Influent pump station
2. Aeration equipment
3. Plant outfall
4. Residuals management facilities
• The addition of a total residual chlorine limit of 28 ug/1 upon expansion to 10.5 MGD.
• The deletion of instream rhonitoring for fecal conform and conductivity.
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 a demand is made, this permit shall be
final and binding.
Please take notice 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 Water Quality or permits
required by the Division of Land Resources, Coastal Area Management Act, or any other Federal or Local
governmental permits may be required.

If you have any questions or need additional information. please contact Ms. Jacquelyn Nowell at
telephone number [phone], extension 512.
Sincerely,
Original Signed By
David A. Goodrich
Kerr T. Stevens
cc: Central Files
Roosevelt Childress/EPA Region IV
Asheville Regional Office / Water Quality Section
Construction Grants and Loans/attn: Cecil Madden
Point Source Compliance /Enforcement Unit
Aquatic Toxicology Unit
NPDES Unit/Permit File

_e
Permit No. NC0041696
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,
Town of Valdese
is hereby authorized to discharge wastewater from a facility located at
Lake Rhodhiss Wastewater Treatment Plant
on Lake Rhodhiss Drive
north of Valdese
Burke County
to receiving waters designated as Lake Rhodhiss (Catawba River) in the Catawba 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 March 1, 2001
This permit and authorization to discharge shall expire at midnight on January 31, 2005
Signed this day January 17, 2001
Original Signed By
David A. Goodrich
Kerr T. Stevens, Director
Division of Water Quality
By Authority of the Environmental Management Commission

Permit No. NC0041696
SUPPLEMENT TO PERMIT COVER SHEET
Town of Valdese •
is hereby authorized to:
Continue to operate a 7.5 MGD wastewater treatment facility consisting of
influent pump station, bar screen, grit removal, primary clarifiers, aeration basins,
• secondary clarifiers, chlorination, gravity sludge thickeners, residual centrifuges,
and residuals composting operation located at Valdese Wastewater Treatment
Plant, on Lake Rhodhiss Drive, north of Valdese, Burke County, and
2. After receiving an Authorization to Construct from the Division of Water Quality,
construct and operate additional wastewater treatment facilities and upgrade the
existing influent pumping, aeration equipment, plant outfall, and residuals
management facilities. The ultimate design capacity after expansion and
modification to existing facilities shall be 10.5. MGD, and
3. Discharge from said treatment works at the location specified on the attached map
into the Lake Rhodhiss (Catawba River), which is classified WS-IV & B CA
waters in the Catawba River Basin.

Facility Information
Latitude: 35°46' 41" Sub -Basin
Longitude: 81°32' 25"
Quad #: D12SE
Stream Class: WS-IV & B CA
Receiving Stream: Catawba River
Permitted Flow: 7,5 MGD, 10.5 MGD
0:-S-OS-31
Town of Valdese -Lake Rhodiss WWTP
NC0041696
Burke County

A (1). EFFLUENT LIMITATIONS AND MONITORING REQUIREMENTS
Permit No. NC0041696
During the period beginning on the effective date of the permit and lasting until December 31, 2001 or expansion to 10.5 MGD, the Permittee is authorized to discharge
from outfall(s) serial number 001. Such discharges shall be limited and monitored by the Permittee as specified below:
EFFLUENT CHARACTERISTICS
LIMITS
MONITORING REQUIREMENTS, _ ,--.�--S�;i. 4
Monthly
Average
Weekly
Average
Daily Maximum
Measurement •
Frequency •
Sample,
Type 2,' •
, £, ?,,RSam !e k
'-''L `Locatlont"
Flow
7.5 MGD
Continuous
Recording
1 or E
BOD5 2
30.0 mg/I
45.0 mg/I
Daily
Composite
E,1
Total Suspended Solids2
30.0 mg/I
45.0 mg/I
Daily
Composite
E,I
NH3-N
Weekly
Composite
E
Dissolved Oxygen
Daily
Grab
Dissolved Oxygen (June 1 through September
30)
3/Week
Grab
U,D
Dissolved Oxygen (October 1 through May 31)
Weekly
Grab
U,D
Fecal Coliform (geometric mean)
200/100 ml
400/100 ml
Daily
Grab
E
pH3
Daily
Grab
E
Phenols
21 trg/I
2/month
Grab
E
Mercury
2/month
Grab
E
Copper
Monthly
Grab
E
Total Residual Chlorine
•
Daily
Giab
Temperature (June 1 through September 30)
3/Week
Grab
U,D
Temperature (October 1 through May 31)
Weekly
Grab
U,D
Total Nitrogen (NO2 + NO3 + TKN)
Monthly
Composite
E
Total Phosphorus
Monthly
Composite
_
E
Chronic Toxicity;
Quarterly
Composite
E
Notes:
1. Sample Locations: E - Effluent, I — Influent , U - Upstream at least 100 feet, D — Downstream 1 mile below discharge at SR 1001. Upstream and downstream samples shall be grab
samples. Stream samples shall be collected three times per week during June, July, August, and September and once per week during the remaining months of the year.
2. The monthly average effluent BOD5 and Total Suspended Residue concentrations shall not exceed 15% of the respective influent value (85% removal).
3� The pH shall not be less than 6.0 standard units nor greater than 9.0 standard units.
4. Chronic Toxicity (Ceriodaphnia) P/F @ 4.8%; January, April, July, October. See Special Conditions of the Supplement to Effluent Limitations A (4).
There shall be no discharge of floating solids or visible foam in other than trace amounts.

A (2). EFFLUENT LIMITATIONS AND MONITORING REQUIREMENTS Permit No. NC0041696
During the period beginning on the January 1, 2002 and lasting until expansion to 10.5 MGD or expiration, the Permittee is authorized to discharge from outfall(s) serial
number 001. Such discharges shall be limited and monitored by the Permittee as specified below:
EFFLUENT CHARACTERISTICS•
LIMITS
MONITORING REQUIREMENTS
. wile. ' -=' is �.-��
Monthly
Average
Weekly
Average
Daily Maximum
Measurement .
Frequency
Sample •
Type '
Sample tx A
Locationl
Flow
7.5 MGD
Continuous
Recording
I or E
BOD5 2
30.0 mgll
45.0 mg/I
Daily •
Composite
E,I
Total Suspended Solids2
30.0 mg/I
45.0 mg/I
Daily
Composite
E,1
NH3-N
Weekly
Composite
E
Dissolved Oxygen
Daily
Grab
E
Dissolved Oxygen (June 1 through September
30)
3/Week
Grab
U,D
Dissolved Oxygen (October 1 through May 31)
Weekly
Grab
U,D
Fecal Coliform (geometric mean)
200/100 ml
400/100 ml
Daily
Grab
E
pH3
Daily
Grab
E
Phenols
21 µg/I
2/month
Grab
E
Mercury
0.25 }tg/I
Weekly
Grab
E
Copper
Monthly
Grab
E
Total Residual Chlorine
Daily
Grab
E
Temperature (June 1 through September 30)
3/Week
Grab
U,D
Temperature (October 1 through May 31)
Weekly
Grab
U,D
Total Nitrogen (NO2 + NO3 + TKN)
Monthly
Composite
E
Total Phosphorus
Monthly
Composite
E
Chronic Toxicity;
Quarterly
Composite
E
Notes:
1. Sample Locations: E - Effluent, I — Influent , U - Upstream at least 100 feet, D — Downstream 1 mile below discharge at SR 1001. Upstream and downstream samples shall be grab
samples. Stream samples shall be collected three times per week during June, July, August, and September and once per week during the remaining months of the year.
2. The monthly average effluent BOD5 and Total Suspended Residue concentrations shall not exceed 15% of the respective influent value (85% removal).
3. The pH shall not be less than 6.0 standard units nor greater than 9.0 standard units.
4. Chronic Toxicity (Ceriodaphnia) P/F @ 4.8%; January, April, July, October. See Special Conditions of the Supplement to Effluent Limitations A (4).
There shall be no discharge of floating solids or visible foam in other than trace amounts.

A (3). EFFLUENT LIMITATIONS AND MONITORING REQUIREMENTS Permit No. NC0041696
During the period beginning upon expansion to 10.5 MGD and lasting until expiration, the Permittee is authorized to discharge from outfall(s) serial number 001. Such
discharges shall be limited and monitored by the Permittee as specified below:
EFFLUENT CHARACTERISTICS
LIMITS
MONITORING REQUIREMENTS ;:. .
Monthly
Average
Weekly
Average
Daily Maximum
Measurement
Frequency •
Sample •
Type
Sample Locations
.,rt: .
Flow
10.5 MGD
Continuous
Recording
I or E
BOD5 2 •
15.0 mg/l
22.5 mg/l
Daily
Composite
E,I
Total Suspended Solids2
30.0 mg/1
45.0 mg/I
Daily
Composite
E,I
NH3-N
4.0 mg/I
Weekly
Composite
E
Dissolved Oxygen3
Daily
Grab
E
Dissolved Oxygen (June 1 through September 30)
3/Week
Grab
U,D
Dissolved Oxygen (October 1 through May 31)
Weekly
Grab
U,D
Fecal Coliform (geometric mean)
200/100m1
400/100 ml
Daily
Grab
E
pH4
Uaily
Grab
E
Phenols
15 pgli '
2/month
Grab
E
Mercury
0.18 µg/I
Weekly
Grab
E •
Copper
2/month
Grab
E
Total Residual Chlorine
28 µg/l
Daily
Grab
E
' Temperature (June 1 through September. 30)
3/Week
Grab
U,D
Temperature (October 1 through May 31)
•
Weekly
Grab
U,D
Total Nitrogen (NO2 + NO3 + TKN)
Monthly
Composite
E
Total Phosphorus
Monthly
Composite
_ E
Chronic Toxicity5
Quarterly
Composite
E
Notes:
1. Sample Locations: E - Effluent, I — Influent , U - Upstream at least 100 feet, D — Downstream 1 mile below discharge at SR 1001. Upstream and downstream samples shall be grab samples.
Stream samples shall be collected three times per week during June, July, August, and September and once per week during the remaining months of the year.
2. The monthly average effluent BOD5 and Total Suspended Residue concentrations shall not exceed 15% of the respective influent value (85% removal).
3. The daily average dissolved oxygen effluent concentrations shall not be less than 5 mgll.
M., The pH shall not be less than 6.0 standard units nor greater than 9.0 standard units.
• N.
5. Chronic Toxicity (Ceriodaphnia) P/F @ 6.6%; January, April, July, October. See Special Conditions of the Supplement to Effluent Limitations A (5).
There shall be no discharge of floating solids or visible foam in other than trace amounts.

Permit No. NC0041696
SUPPLEMENT TO EFFLUENT LIMITATIONS
AND MONITORING REQUIREMENTS
SPECIAL CONDITIONS
A (4). CHRONIC TOXICITY PERMIT LIMIT (QUARTERLY) @ 7.5 MGD
The effluent discharge shall at no time exhibit observable inhibition of reproduction or significant mortality to Ceriodaphnia
dubia at an effluent concentration of 4.8 %.
The permit holder shall perform at a minimum, quarterly monitoring using test procedures outlined in the "North Carolina
Ceriodaphnia Chronic Effluent Bioassay Procedure," Revised February 1998, or subsequent versions or "North Carolina Phase
II Chronic Whole Effluent Toxicity Test Procedure" (Revised -February 1998) or subsequent versions. The tests will be
performed during the months of January, April, July, and October. Effluent sampling for this testing shall be performed at
the NPDES permitted final effluent discharge below all treatment processes.
If the test procedure performed as the first test of any single quarter results in a failure or ChV below the permit limit, then
multiple -concentration testing shall be performed at a minimum, in each of the two following months as described in "North
Carolina Phase II Chronic Whole Effluent Toxicity Test Procedure" (Revised -February 1998) or subsequent versions.
The chronic value for multiple concentration tests will be determined using the geometric mean of the highest concentration
having no detectable impairment of reproduction or survival and the lowest concentration that does have a detectable
impairment of reproduction or survival. The definition of "detectable impairment," collection methods, exposure regimes, and
further statistical methods are specified in the "North Carolina Phase II Chronic Whole Effluent Toxicity Test Procedure"
(Revised -February 1998) or subsequent versions.
All toxicity testing results required as part of this permit condition will be entered on the Effluent Discharge Monitoring Form
(MR-1) for the months in which tests were performed, using the parameter code TGP3B for the pass/fail results and THP3B
for the Chronic Value. Additionally, DWQ Form AT-3 (original) is to be sent to the following address:
Attention: Environmental Sciences Branch
North Carolina Division of
Water Quality
1621 Mail Service Center
Raleigh, North Carolina 27699-1621
Completed Aquatic Toxicity Test Forms shall be filed with the Environmental Sciences Branch no later than 30 days after the
end of the reporting period for which the.report is made.
Test data shall be complete, accurate, include all supporting chemical/physical measurements and all concentration/response
data, and be certified by laboratory supervisor and ORC or approved designate signature. Total residual chlorine of the
effluent toxicity sample must be measured and reported if chlorine is employed for disinfection of the waste stream.
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 the permittee fail to monitor during a month in which toxicity monitoring is required, monitoring will be required
during the following month.
Should any test data from this monitoring requirement 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,
minimum control organism reproduction, 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.

Permit No. NCOO4169G
SUPPLEMENT TO EFFLUENT LIMITATIONS
AND MONITORING REQUIREMENTS
SPECIAL CONDITIONS
A (5). CHRONIC TOXICITY PERMIT LIMIT (QUARTERLY) ® 10.5 MGD
The effluent discharge shall at no time exhibit observable inhibition of reproduction or significant mortality to Ceriodaphnia
dubia at an effluent concentration of 6.6%.
The permit holder shall perform at a minimum, auarterl' monitoring using test procedures outlined in the "North Carolina
Ceriodaphnia Chronic Effluent Bioassay Procedure," Revised February 1998, or subsequent versions or "North Carolina Phase
II Chronic Whole Effluent Toxicity Test Procedure" (Revised -February 1998) or subsequent versions. The tests will be
performed during the months of January, April, July, and October. Effluent sampling for this testing shall be performed at
the NPDES permitted final effluent discharge below all treatment processes.
If the test procedure performed as the first test of any single quarter results in a failure or ChV below the permit limit, then
multiple -concentration testing shall be performed at a minimum, in each of the two following months as described in "North
Carolina Phase II Chronic Whole Effluent Toxicity Test Procedure" (Revised -February 1998) or subsequent versions.
The chronic value for multiple concentration tests will be determined using the geometric mean of the highest concentration
having no detectable impairment of reproduction or survival and the lowest concentration that does have a detectable
impairment of reproduction or survival. The defmition of "detectable impairment," collection methods, exposure regimes, and
further statistical methods are specified in the "North Carolina Phase II Chronic Whole Effluent Toxicity Test Procedure"
(Revised -February 1998) or subsequent versions.
All toxicity testing results required as part of this permit condition will be entered on the Effluent Discharge Monitoring Form
(MR-1) for the months in which tests were performed, using the parameter code TGP3B for the pass/fail results and THP3B
for the Chronic Value. Additionally, DWQ Form AT-3 (original) is to be sent to the following address:
Attention: Environmental Sciences Branch
North Carolina Division of
Water Quality
1621 Mail Service Center
Raleigh, North Carolina 27699-1621
Completed Aquatic Toxicity Test Forms shall be filed with the Environmental Sciences Branch no later than 30 days after the
end of the reporting period for which the report is made.
Test data shall be complete, accurate, include all supporting chemical/physical measurements and all concentration/response
data, and be certified by laboratory supervisor and ORC or approved designate signature. Total residual chlorine of the
effluent toxicity sample must be measured and reported if chlorine is employed for disinfection of the waste stream.
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 the permittee fail to monitor during a month in which toxicity monitoring is required, monitoring will be required
during the following month.
Should any test data from this monitoring requirement 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,
minimum control organism reproduction, 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.

Re: NC0041696 - Town of Valdese permit
Subject: Re: NC0041696 - Town of Valdese permit
Date: Mon, 08 Jan 2001 13:54:39 -0500
From: Harold Saylor <[e-mail]>
Organization: NC DENR - Asheville Regional Office
To: Jackie Nowell <jackie.nowell @ncmail.net>
Jackie, we concur with renewal of the referenced permit for the Town of
Valdese Wastewater Treatment Plant. Let me know if you need anything
further. H Saylor
Jackie Nowell wrote:
> Hello Mr. Saylor, I contacted you in December about DEH approval on the
> renewal of this permit that discharges into Lake Rhodhiss in Burke Co.
> In our last phone call, you indicated that other staff in your office
> would review this. Please let me know the status of your review,
> because your information will allow me to proceed with the reissuance
> this permit. Thank you.
Harold Saylor - [e-mail]
North Carolina Dept. of Environment and Natural Resources
Asheville Regional Office - Merrimon Ave. Office
Division of Environmental Health - Public Water Supply
852 Merrimon Ave.
Asheville, NC 28804
Tel: [phone]
Fax: [phone]
Harold Saylor <Harold.Saylor@ncmail.n_e_b
NC DENR - Asheville Regional Office
Division of Environmental Health - Public Water Supply
1 of 1 1/8/01 2:30 PM

Permit Notes
NC0041696
Background
The Town of Valdese has requested renewal of existing permit. Facility is a 7.5 MGD
plant that discharges into Lake Rhodhiss (the Catawba River). The lake is fully
supporting its uses. The receiving stream is classified WS-IV & B CA (critical area).
The Catawba River chain lakes have regulated flow from the dams. The minimum flow
that has been used in the past WLAs has been 228.7 cfs.
Existing limits at 7.5 MGD are BODS= 30 mg/1, NH3 monitoring, TSS =30 mg/1, Fecal =
200/ 100m1, monthly monitoring of TN and TP, a phenols limit of 21 ug/1, chronic
toxicity limit of 4.8% in JAN APR JUL OCT. Instream monitoring for DO, fecal, temp
and conductivity is currently required. Fecal and conductivity will be dropped.
Spec limits for expansion to 9.5 and 11.5 MGD, were completed in 1991 and 1998.
DWQ recommended BPJ limits of 15 mg/1 BOD5, 4 mg/1 NH3 and DO > 5 mg/1. May
need some revisions of nitrogenous inputs of direct dischargers into the lake. Chronic
tox tests of 6 and 7% would also be recommended.
Preliminary recommendation for 10.5 MGD - BPJ limits of 15/4/5, TRC = 28 ug/1,
phenols and mercury limit, copper, zinc and sulfates monitoring in the NPDES
permit, Chronic quarterly test @ 6.6%.
Continued instream monitoring for temperature and DO. Recommend that facility
conduct TP optimization study for plant because of the elevated TP levels
discharged over the past few years.
Permit Application Info
Valdese also serves the Town of Hildebran, Drexel, Rutherford College, Connelly
Springs, and Eastern Burke Co. for a total of 13,430 people served. Estimated average
monthly flow from all industrial sources - 3.83 MGD. Total permitted monthly flow
from all industrial sources - 5.662 MGD
Sills - updated per 7/31/00 conversation with Andria Pressley, pretreatment
coordinator. The Valdese WWTP has 80% industrial waste and 20% domestic waste.
Sometimes flow goes as high as 90% industrial.
• Waldensian Bakery - bakery - 0.071 MGD - intermittent
• Valdese Weavers (Rutherford College and Lovelady) - upholstery fabric - 0.656
MGD- intermittent (BOD5, TSS)
• Valdese Textiles - upholstery fabric - 0.130 MGD - intermittent (BOD5, TSS)
• Valdese Manufacturing Co. - yarn - 0.770 MGD - intermittent
• (BOD5, TSS, Pb, Zn - 826,000)
• Houston Hosiery - socks - 0.029 MGD - intermittent
• VNC Textiles -fabrics and cloths - 0.589 MGD - intermittent
• Carolina Mills - fabrics and cloth - 1.117 MGD- intermittent (BOD5, TSS, As, Cd,
Cu, Cn, Pb, Hg, Ni, Ag, Cr, Zn)
• Burke Mills, Inc. - yarn- 0.361 MGD- intermittent - (BOD5, TSS, Zn, Cr)
• Alba Waldensian - ladies undergarments -0.083 MGD - intermittent (BOD5, TSS,
Zn, Cu)
• Robinson Hosiery - textile - 0.024, (0.050 MGD per Andria Pressley on 7/31) -
intermittent
*(info in parentheses is from 1995 application)

Permit Notes
NC0041696
Page 2
7/25/00 call from Dan Blaisdell of Construction Grants. - Meeting scheduled on
7/26 at 10 am with the engineers from Valdese. Construction Grants has already
approved and
issued an ATC for the Town. Reviewed the 201 plan, however when the Town
submitted the plans and specs, they didn't have everything they needed to go to 10.5
MGD. Although the
Town can construct, they can't pass flow greater than 7.5 MGD. Valdese wants to
resubmit their application for a conditional expansion to 10.5 MGD. (This would be
considered a major modification of the permit and has not been requested as of yet.)
According to CG, Valdese must address and complete three things for the expansion to
10.5 MGD. 1) Sludge handling, 2) an internal pump station, and 3) the effluent outfall
is too small. They are meeting with CG, and NPDES to make sure that all needed info
is in the application request.
5/26/00 - Received note from Michelle Woolfolk - RO has provided information on
TP loads from Valdese. TP concentrations have gradually increased on the years, in
1994 avg. was approximately 3.5 mg/1, in 1995 it was 6.5 mg/1, in 1996 - 5.7 mg/1, in
1997 - 7.4 mg/1, in 1998 -5.7 mg/1, in 1999 - 5.3 mg/1, thru May 2000 - 3.8 mg/l.
Possible factors contributing to the TP increase may be a change in the ORC between
1994 and 1995, solids loss due to clarifier work, and solids loss associated with I&I.
The new operator failed to maintain sufficient oxygen concentrations in the aeration
basin. Still tries to maintain an anoxic zone within the aeration basin. Low DO
concentrations and anoxic zones may have raised the TP discharged in 1995 and
subsequently. Certain organisms release soluble inorganic phosphorus under
anaerobic conditions. Modeling Unit recommending optimization at the plant.
3/24/00 - email from Tom Belnick - ESB meeting on Lake James/Rhodhiss/Hickory
- Concerned about increasing TP loading from Valdese. The load does not appear to
impact Lake Rhodhiss, some may be exported downstream to Lake Hickory, since
Rhodhiss doesn't appear to be a TP sink. Coleen recommends asking them to
evaluate why TP load is increasing, indicate concern about downstream lake, and
possibly have them do TP optimization study. These items should be placed in
the cover letter.
1999 Catawba River Basinwide Management Plan (p. 94) -DWQ is using a model to
develop a management strategy to protect water quality of Rhodhiss Lake. USGS model
evaluated the response of chlorophyll a levels in the lake to different nutrient reduction
scenarios. Reductions of TP and TN considered at the headwaters and at the Valdese
WWTP. With input from local stakeholders, will develop a management strategy for
controlling nutrient inputs to Rhodhiss Lake. Point sources contribute 22% of TP load
and 27% of TN load. Nutrient strategy will be described in the next basin plan.
Review of Compliance Data
Thus far in 2000, Valdese has had one permit exceedence for TSS in March. Averages
for Qw= 5.4 MGD, BODS = 5.0 mg/1, NH3 = 0.35 mg/1, TSS = 22.1 mg/1, TN = 3.6
mg/1, TP = 3.8 mg/l.
In 1999, Two exceedences of TSS in June and November. Averages were Qw = 5.2 MGD,
BODS =5.8 mg/1, TSS = 26.9 mg/1, and NH3 = 0.23 mg/1, TN = 4.4 mg/1, TP = 5.4 mg/1.

Permit Notes
NC0041696
Page 3
In 1998, One BOD5 violation and 4 TSS violations. Qw averaged 5.5 MGD, BOD= 7.3
mg/1, TSS = 50 mg/1, NH3 = 0.23 mg/1, TN = 7.4 mg/1, TP = 5.7 mg/1.
In 1997, No exceedences of permit limits. Qw averaged 4.9 MGD, BOD= 3.9 mg/1, TSS =
13.4 mg/1, NH3 = 0.39 mg/1, TN = 6.3 mg/1, TP = 7.4 mg/1
Chlorine values are relatively high, the averages ranged from 0.535 mg/1 to 1.04 mg/1.
Maximum values reported are 1.9 mg/1 to 4.1 mg/1.
During 2000, the flow average has been 5.4 MGD this is approximately 72% of design
flow of 7.5 MGD. In 1999, the flow average was 5.2 MGD, which was 69% of capacity.
In 1998, the flow average was 5.5 MGD, which was 73% of capacity.
Toxicity Test Results: Existing Chronic Toxicity Test @ 4.8% sampled in JAN APR JUL
OCT. Has consistently PASSed the tox test since July 1996. Two Late tests in 1998.
Last FAILs in April and May 1996.
Reasonable Potential Analysis:
Initial results indicate that mercury should be limited. Per A. Pressley, the reported
mercury value for May 9th is not correct. Instead of 2.4 ug/1, the actual value is 1.2
ug/1. Will fax the corrected data to NPDES. The replacement of the Hg value did not
change the previous result of the RPA. Hg should still be limited, the maximum
predicted value is lower.
A sulfates limit will be placed in the permit at 7.5 MGD and 10.5 MGD. The allowable
concentration for sulfates is very high (5174 mg/1) and the maximum predicted value is
approximately three times greater (17535 mg/1). Therefore will recommend a sulfates
limit for the protection of the WS classification (already in the LTMP program).
A chromium limit will be placed in the permit at 10.5 MGD based on the reasonable
potential analysis.
Copper,and zinc monitoring will be added based on the reasonable potential analysis.
Instream Data
Instream monitoring for dissolved oxygen and temperature will be continued. Sites will
be upstream 100 feet of discharge point and downstream 1 mile below discharge at
SR1001. Monitoring for fecal coliform and conductivity will be deleted due to new DWQ
policy for 100% domestic dischargers.
April - October, 1997 - 1999: All data looks good, no instream violations of DO. DO
values range from 8 to 10 mg/1, upstream and downstream. There were no
exceedances of the fecal coliform standard instream. Instream BOD5 averages 2 mg/1.
Correspondence File Info
6/19/2000 - NOV and assessment for civil penalties of $1329.46 for violation of Total
Suspended Residue and fecal coliform discharge limits in March 2000.
3/20/2000 - Pretreatment Annual Report - in compliance however "waste reduction
should receive additional attention" per ARO.

Permit Notes
NC0041696
Page 4
3/8/2000 - Received $1079.46 in payment of civil assessment
10/20/1999 - Effluent value of 9 ug/1 reported for phenols.
10/ 13/ 1999 - Compliance Inspection Report - in compliance
9/24/99 - NOV and assessment for civil penalties of $1079.46 for violation of Total
Suspended Residue discharge limits in June 1999.
6/ 14/ 1999 - Pretreatment Compliance Inspection - program well run
1 /7/99 - Compliance Evaluation Inspection to assess the loss of solids during
preventative maintenance and repair of a secondary clarifier which started on 12/8/98.
11 / 16/98 - Payment acknowledgement of $1103.00
10/ 16/98 - NOV and assessment for civil penalties of $1103.00 for violation of Total
Suspended Residue discharge limits in July 1998.
6/26/98 - Sludge spill acknowledgement from ARO on report
6/22/98 - NOV for TSS
12/30/97 - NOV during the CSI- phenols limit exceeded. No corrective actions
indicated.
7/26/96 - NOV for tox test in May 1996
6/26/96 - NOV for tox test in April 1996
4/29/96 - NOV for TSS
1/29/96 - NOV for TSS and fecal coliform
##########################
Recommend renewal of existing NPDES limits with some changes.
• Instream monitoring for fecal coliform and conductivity will be deleted due to
new DWQ policy.
• The addition of mercury and sulfates limits at 7.5 MGD and 10.5 MGD based
on reasonable potential analysis of LTMP data.
• The addition of a chromium limit at 10.5 MGD based on reasonable potential
analysis of LTMP data.
• The addition of copper and zinc monitoring at 7.5 MGD and 10.5 MGD based
on reasonable potential analysis of LTMP data.
• Facility must conduct a TP optimization study to determine the sources of
high effluent TP values.

Permit Notes
NC0041696
Page 5
8/8/00 - Review of engineering narrative in support of modification of permit for
expansion to 10.5 MGD: The request is for an additional 3 MGD of wasteflow to
accommodate 500,000 gallon per day from Valdese Manufacturing Co. and to handle
future wastewater treatment needs of anticipated residential, commercial area, and
industrial growth in the Valdese portion of the regional Burke County. The expansion
involves the replacement of the existing equipment that is in deteriorated conditions,
upgrading equipment within the existing treatment structures and the addition of new
facilities. Valdese serves 5 towns with a total population of approx. 13,500 and 10
SIUs. Flow projections indicate that the facility will reach the average daily flow
capacity of 7.5 MGD in 2008. In 2007, would have to submit plans and specs for the
future improvements and construction would be completed in 2008.
During 2000, the flow average has been 5.4 MGD this is approximately 72% of design
flow of 7.5 MGD. In 1999, the flow average was 5.2 MGD, which was 69% of capacity.
In 1998, the flow average was 5.5 MGD, which was 73% of capacity.
1. Average Daily Industrial Flow ---
2. Permitted Monthly Industrial Flow ---
3. Current NPDES Permitted Flow
4. Difference allowed for domestic/other flows
3.83 MGD
5.662 MGD
7.5 MGD
1.838 MGD (#3 - #2)
3.67 MGD (#3 - #1)
If facility will reach 7.5 MGD capacity in eight years in 2008, when will Valdese
Manufacturing Co. flow of 0.5 MGD be needed? Town currently has the capacity to
accept this flow now and still have additional room less than 7.5 MGD. Need to review
population growth information for all towns.
8/ 30/ 00 - telecon with Charles Davis of The Wooten Company- asked him of written
request from Valdese Manufacturing Co. requesting 500,000 GPD of additional flow
from the Town. Said that he was not sure that all 500,000 GPD was to come from just
one company but more than one. He will check on sending a letter of verification for
flow.
9/1/00 - received fax of 7/23/98 letter from Valdese Manufacturing Co. where they
"expect to expand their operation in the next 5 to 7 years by 0.5 MGD". They requested
that 0.5 MGD of additional capacity be included in the proposed expansion and
reserved for Valdese Mfg.
9/30/00 - peer review had raised questions about the flow justification for expansion to
10.5 MGD. Consulted with DAG who said that the flow justification and projections
have been reviewed and approved by Construction Grants. FONSI has been approved
for 10.5 MGD and their decision will stand. 201 Plan has been approved and we will
issue the permit with 7.5 MGD and 10.5 effluent limits pages.
DWQ Response to Valdese written comments rec'd 10/27/00
1. Valdese requests change on supplement page from "aeration equipment
including additional blowers" to "aeration equipment" only. - DWQ concurs

Permit Notes
NC0041696
Page 5
8/8/00 - Review of engineering narrative in support of modification of permit for
expansion to 10.5 MGD: The request is for an additional 3 MGD of wasteflow to
accommodate 500,000 gallon per day from Valdese Manufacturing Co. and to handle
future wastewater treatment needs of anticipated residential, commercial area, and
industrial growth in the Valdese portion of the regional Burke County. The expansion
involves the replacement of the existing equipment that is in deteriorated conditions,
upgrading equipment within the existing treatment structures and the addition of new
facilities. Valdese serves 5 towns with a total population of approx. 13,500 and 10
SIUs. Flow .projections indicate that the facility will reach the average daily flow
capacity of 7.5 MGD in 2008. In 2007, would have to submit plans and specs for the
future improvements and construction would be completed in 2008.
During 2000, the flow average has been 5.4 MGD this is approximately 72% of design
flow of 7.5 MGD. In 1999, the flow average was 5.2 MGD, which was 69% of capacity.
In 1998, the flow average was 5.5 MGD, which was 73% of capacity.
1. Average Daily Industrial Flow ---
2. Permitted Monthly Industrial Flow ---
3. Current NPDES Permitted Flow
4. Difference allowed for domestic/other flows
3.83 MGD
5.662 MGD
7.5 MGD
1.838 MGD (#3 - #2)
3.67 MGD (#3 - #1)
If facility will reach 7.5 MGD capacity in eight years in 2008, when will Valdese
Manufacturing Co. flow of 0.5 MGD be needed? Town currently has the capacity to
accept this flow now and still have additional room less than 7.5 MGD. Need to review
population growth information for all towns.
8/30/00 - telecon with Charles Davis of The Wooten Company- asked him of written
request from Valdese Manufacturing Co. requesting 500,000 GPD of additional flow
from the Town. Said that he was not sure that all 500,000 GPD was to come from just
one company but more than one. He will check on sending a letter of verification for
flow.
9 / 1 / 00 - received fax of 7 / 23 / 98letter from Valdese Manufacturing Co. where they
"expect to expand their operation in the next 5 to 7 years by 0.5 MGD". They requested
that 0.5 MGD of additional capacity be included in the proposed expansion and
reserved for Valdese Mfg.
9/30/00 - peer review had raised questions about the flow justification for expansion to
10.5 MGD. Consulted with DAG who said that the flow justification and projections
have been reviewed and approved by Construction Grants. FONSI has been approved
for 10.5 MGD and their decision will stand. 201 Plan has been approved and we will
issue the permit with 7.5 MGD and 10.5 effluent limits pages.
DWQ Response to Valdese written comments rec'd 10/27/00 and resulting
telephone conversation with .Alan Abee, ORC of Valdese WWTP on December 15,
2000.
1. Valdese requests change on supplement page from "aeration equipment including
additional blowers" to "aeration equipment" only. - DWQ concurs

2. Valdese disagrees with limits for mercury and sulfates at 7.5 MGD and 10.5
MGD - DWQ has performed reasonable potential analyses using 1999 and 2000
data. Submitted DMR data showed mercury hits of 1.2 ug/1 (corrected from 2.4
ug/1), 0.3 ug/1 and 0.8 ug/1 with an allowable concentration of 0.25 ug/1 for
mercury at 7.5 MGD (using 229 cfs as the s7Q10). Our analyses indicate that a
limit is necessary for mercury at 7.5 MGD. Valdese' admits that hits of 0.3 ug/1
have been recorded. These values show the potential and the actuality of the
mercury standard being exceeded instream. The allowable concentration for
mercury at 10.5 MGD is 0.18 ug/1. The evaluation of the submitted data predicts
that this limit would also be violated with an increase to 10.5 MGD. Based on
this analysis, a limit was recommended for both 7.5 MGD and 10.5 MGD.
** The Division recommends a compliance schedule for mercury because
facility has never had limit before. Sludge data and compost samples indicate
Hg below detection levels. They also have questions about the lab results for
Hg, since 1 very high value was reported. Town believes Hg would be in the
system more consistently if it was a real problem. Recommend twice per
month monitoring for twelve months, after which the mercury limit would be
applied at both flows. If Valdese has twelve months of Hg below detection
levels, they can request that the Division reevaluate whether the limit should
be given.
• Sulfates limits - After further evaluation of the data used during our analysis, it
was determined that sulfates limits at 7.5 MGD and 10.5 MGD are no longer
required. More recent data submitted by the Town was more representative of the
current treatment for this constituent. In addition, sulfates will be monitored
quarterly in the Town's Long Term Monitoring Plan (LTMP) and this data can be
evaluated upon next permit renewal.
3. Cr limit at 10.5 MGD - The highest reported value was 107 ug/1, based on the
reasonable potential analysis and safety factors used, it was determined that at
10.5 MGD, the potential existed for an exceedance of the limit of 753 ug/1.
However, because most of the other Cr values averaged less than 15 ug/1. we will
concur with dropping the limit at 10.5 MGD and will use the data from LTMP
monitoring to evaluate Cr upon the next permit renewal.
4. Cu and Zn monitoring - the data for these parameters are compared to State
action levels and are currently being evaluated by EPA and NC for consideration of
water quality standards. Allowable concentrations are 145 ug/1 for Cu and 1035
ug/1 for Zn. The highest Cu values were 90 ug/1, 55 ug/1, and 50 ug/1 and after the
analysis it was projected to exceed the allowable. It was included in the NPDES
permit because more than quarterly monitoring is needed. The highest Zn value
reported was 461 ug/1 (if this was a lab error, Valdese did not question the result),
all other values were below 69 ug/1. The allowable concentration of 1035 ug/1 is
projected to be exceeded in the reasonable potential analysis. After further
evaluation, we recommend monthly copper monitoring in the NPDES permit
and zinc monitoring will be dropped from the permit and continued quarterly
in the LTMP.
5. Phenols is an aesthetic standard to protect water supplies from taste and odor
problems due to chlorinated phenols. There are two water supply intakes located
approximately 5 miles below the Valdese WWTP. (These are water treatment
facilities for Lenoir and Granite Falls.) Because of the location of these intakes and

based on values of 23 ug/1, 24 ug/1, 28 ug/1 and 31 ug/1 that have occurred within
the past two years, DWQ recommends that the phenols limits of 21 ug/1 @ 7.5
mg/1 and 15 ug/1 @ 10.5 mg/1 remain in the permit. Will review the
compliance period for phenols and determine whether weekly average limits
can be given, per request of the Town.
6. We will concur with the extension for the completion of the total phosphorus
optimization study to June 30, 2002 for the purpose of including all seasons and
data compilation by Valdese.
7. Instream monitoring for dissolved oxygen and temperature shows the impact of your
discharge on the receiving stream. We review the data to determine whether the DO
standard of 5 mg/1 is being protected and whether the instream temperature is
elevated by the discharge. The instream monitoring of these parameters will not
be removed from the permit.
8. The sentence regarding 85% removal cannot be removed from the NPDES permit it
is required by federal regulation 40 CFR 133 for secondary treatment. We can
consider modification from 85% percent removal to a value more reflective of the
BOD5 and TSS coming into your plant. Central Office must consult with ARO.
Tel

TOWN OF VALDESE
LAKE RHODHISS WWTP
2100 Lake Rhodhiss Drive
P.O. Box 339
Valdese, North Carolina 28690
879 - 2131
October 25, 2000
Ms. Jacquelyn M. Nowell
NPDES Unit
Division of Water Quality
1617 Mail Service Center
Raleigh, N.C. 27699-1617
Ref: Draft NPDES Permit
No. NC 0041696
Lake Rhodhiss WWTP
Town of Valdese
Dear Ms. Nowell
After a thorough review of the Draft copy of our proposed NPDES permit, we
have several concerns and questions in regards to the limits and monitoring requirements.
All of these items will cause a drastic increase in the cost of operations. With the
changes in the economy, instability of the textile industry, along with the ever increasing
cost of daily operations, I am concerned with the increased cost associated with these
limits and parameters as well as the reasoning behind them being included in the permit.
I understand the needs for limits and parameters to be monitored. However, I
have questions on the following items:
1. Mercury Limit
2. Sulfate Limit
3. Chromium Limits
4. Monitoring for Copper & Zinc
5. Continued Limits on Phenols and increased monitoring
6. TP optimization study
7. Stream Sampling
I would like to request a change to the phrase in Item 2 of the supplement to permit
cover sheet be revised to read "aeration equipment" rather than "aeration equipment
including additional blowers".

All testing results included in the numbers below are from January 1998 to the
present. Low numbers are listed first and high numbers are listed second.
# 1 & #2) After reviewing data from the past 3 years, I do not agree with placing a
limit of 0.25 ug/1 for mercury and 5174 mg/1 limit on sulfates for a 7.5
MGD plant and 0.18 ug/1 for mercury and 3767 mg/1 on sulfates at 10.5
MGD. My reasoning behind the disagreements are that we have continued
to have mercury #'s of <0.0002 mg/1, with the exception of 2 times that
we had results of 0.0003 mg/1 and a 1 time result of 0.012 mg/1. I do not
believe that these numbers should require a sudden implementation of
limits on mercury.
Sulfates have been between a low of 210 mg/land a high of 691 mg/1.
Why do you suggest a limit of 5174 mg/1 with 2 times a month frequency?
Once again, this does not show a need for limits.
#3) Chromium limits @ 753 ug/1 for a 10.5 MGD plant is also questionable.
The testing results that we have for the time frame range from <0.005 mg/1
to 0.107 mg/1. There seems to be no merit for any type of limits.
#4) Copper and Zinc monitoring on a 2 time per month basis is not necessary.
Copper numbers have been between 0.018 mg/1 and 0.055 mg/1. The
0.055 mg/1 is the highest number that we have had. The next highest
number is 0.031 mg/1. Request that we go back to quarterly monitoring
with the LTM or Annual Metals
#5) During the past 5 years, we have had only a very small number of times
that the phenols have been above the detection level. And of those, only 5
or 6 times have they been > 0.021 mg/1. We are requesting that the limit
be dropped and the monitoring frequency be dropped.
#6) The total phosphorus optimization study that you have recommended is
under consideration at this time. However, we are requesting that the time
frame be extended until June 30, 2002. This will allow us to do an in
depth study that includes all seasons and give us time to compile our data.
#7) With the deletion of in stream monitoring for fecal coliform and
conductivity, we will only have to monitor the parameters for dissolved
oxygen and temperature. What will these numbers be used for; can we not
drop these also?

A final concern is #2 of the notes: I would like the complete sentence deleted
concerning 85% removal rate. Due to the nature of our waste (80-85 %
textile dyes) we have a low number of TSS coming in and low numbers of
BOD. However, instead of the normal amount of waste generated by
BOD conversions, we have to remove 3 — 4 times the amount of waste.
The amount of waste generated creates more solids and pushes us on the
85% removal rate. Please consider the removal of this item.
If we were having problems with metals, nutrients, phenols, or any other toxic
chemicals, would they not be showing up in our Toxicity testing? We
typically have numbers in the negative calculated t values. Also, test
results show that the second part of the test does better than the control
setup.
If there are any other information needed to qualify our comments and test results,
the Town of Valdese staff is available to meet with or discuss these
objections to the draft NPDES permit. Please contact the Town of
Valdese at 828-879-2131 to schedule a meeting if necessary.
Thank you for your consideration and assistance in this matter.
Sincerely,
David "Alan" Abee, Superintendent/ORC
Lake Rhodhiss WWTP
Cc: Jeff Morse, Town Manager
The Wooten Company

Wooten
Company
Engineering
Planning
Architecture
120 N. Boylan Avenue
Raleigh, NC
27603
October 25, 2000
Ms. Jacquelyn M. Nowell
NPDES Unit
Division of Water Quality
1617 Mail Service Center
Raleigh, North Carolina 27699-1617
Re: Draft NPDES Permit
No. NC 0041696
Lake Rhodhiss WWTP
Town of Valdese
TWC No. 2749
Dear Ms. Nowell:
On behalf of the Town of Valdese, Mr. Jeff Morse, Manager of the Town of Valdese,
has requested that The Wooten Company advise you that the Town does not agree
with the above referenced draft NPDES permit. The areas of objection include:
1. The addition of mercury and sulfate limits
2. The addition of chromium limit
3. The addition of effluent monitoring for copper and zinc
919-828-0531 4. The length of time allowed to conduct the Total Phosphorus optimization
Fax: [phone] study.
Since 1936
It is requested that the additional limits not be included in the final permit and that the
time for the Total Phosphorus optimization study be extended to June 30, 2002 in
order that all seasons can be included in the study. It is further requested that the
phrase in Item 2 of the Supplement to Permit cover sheet be revised to read "aeration
equipment" rather than "aeration equipment including additional items." The Town
staff would also like to provide information and discuss the phenols limits.
The Town staff and the staff of The Wooten Company are available to meet and
discuss these objections in the draft NPDES permit. Please contact the Town of
Valdese to schedule a meeting.
Thank you for your assistance in this matter.
Sincerely,
THE WOOTEN COMPANY
Coy M. Batten
c: Town of Valdese

County
Burke
NPDES Permit Number NC0041696, Valdese, Town -Lake Rhodhiss WWTP. P. O. BOX 339, Valdese, NC 28690 has
applied for a modification for a facility located in Burke County discharging treated wastewater into Lake Rhodhiss
(Catawba River) in the Catawba River Basin. Currently BOD5, NH3, DO and phenols are water quality limited. This
discharge may affect future allocations in this portion of the receiving stream.
f
1
CLIPPING OF
LEGAL
ADVERTISEMENT
ATTACHED HE E
Nora
NORTH CAROLINA
BURKE 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,
PUBLIC NOTICE'
STATE OF NORTH CAROLINA
ENVIRONMENTAL MANAGEMENT
COMMISSION/NPDES UNIT
1617 MAIL SERVICE CENTER,
RALEIGH, NC 27699-1617
NOTIFICATION OF INTENT TO ISSUE
A NPDES WASTEWATER PERMIT
On the basis of thorough review and application of NC General Statute
143.21, Public law 92-500 and other lawful standards and regulations,
the North Carolina Environmental Management Commission proposes to
issue a National Pollutant Discharge Elimination System (NPDES)
wastewater discharge permit to the person(s) listed on the attached pages
effective 45 days from the publish date of this notice.
Written comments regarding the proposed permit will be accepted until
30 days alter the publish date of this notice. All comments received prior
to that date are considered in the final determinations regarding the
proposed permit. The Director of the NC Division of Water Quality may
decide to hold a public meeting for the proposed permit should the
Division receive a significant degree of public interest.
Copies of the draft permit and other supporting information on file to
determine conditions present in the draft permit are available upon
request and payment of the costs of reproduction.Mail comments and/or
requests for information to the NC Division of Water Quality at the
above address or call Ms. Christie Jackson at [phone], extension
538. Please include the NPDES permit number (attached) in any
communication. Interested persons may also visit the Division of Water
Quality at 512 N. Salisbury Street, Raleigh, NC 27604-1148 between the
hours of 8:00 a.m. and 5:00 p.m. to review information on lilt.
NPDES Permit Number NC0041696, Valdese, Town -Lake Rhodhiss
WWTP. P.O. Box 339, Valdese, NC 28690 has applied for a modification
for a facility located in Burke County discharging treated wastewater into
Lake Rhodhiss (Catawba River) in the Catawba River Basin. Currently
BODS, NH3, DO and phenols are water quality limited. This discharge may
affect future allocations in this portion of the receiving stream.
Notary Public
1 H. Eugene Willard
sworn, deposes and says:
lisher
:BALD, published, issued, and
lass mail in Morganton, in said
that he (she) is authorized to
and sworn statement; that the
1 advertisement, a true copy of
hereto, was published in The
following dates:
R
,wspaper in which such notice,
or legal advertisement was
to time of each and every such
rspaper meeting all of the
lualifications of Section 1-597
Mutes of North Carolina and
er within the meaning of
to General Statutes of North
3ctober, 20 t 0
blisher or Manager
ed before me,
tober, 2000
MY ea? ssion Expires
Y r mission Expires 8-22-2004
Wednesday, September 27, 2000
1617 Mail Service Center. Raliegh. North Carolina 27699-1617 - Telephone [phone] FAX [phone]
An Equal Opportunity Affirmative Action Employer - 50% Recycled / 10% post -consumer paper

DENR/DWQ
FACT SHEET FOR NPDES PERMIT DEVELOPMENT
NPDES No. NC0041696
Facility Information
Applicant/Facility Name:
Town of Valdese WWTP
Applicant Address:
P.O. Box 339 Valdese, N.C. 28690-0339
Facility Address:
On Lake Rhodhiss Drive
Permitted Flow
7.5 MGD; expansion to 10.5 MGD
Type of Waste:
Domestic and Industrial
Facility/Permit Status:
Renewal and Modification
Facility Classification
IV
County:
Burke
Miscellaneous
Receiving Stream:
Lake Rhodhiss
(Catawba River)
Regional Office:
Asheville
Stream Classification:
WS-IV & B CA
USGS Topo Quad:
D12SE
303(d) Listed?:
No
Permit Writer:
Jackie Nowell
Subbasin:
03-08-31
Date:
August 30, 2000
Drainage Area (mi2):
Lake
Summer 7Q10 (cfs)
228.7 (min.
release + runoff)
. .
-: ,
Winter 7Q10 (cfs):
-
Average Flow (cfs):
-
IWC (%):
4.8% @ 7.5
MGD, 6.6%
10.5 MGD
Primary SIC Code:
4952
SUMMARY OF FACILITY INFORMATION AND WASTELOAD ALLOCATION
The Town of Valdese has requested renewal of existing permit. Facility is a 7.5 MGD plant that
discharges into Lake Rhodhiss (the Catawba River). The lake is fully supporting its uses. The
receiving stream is classified WS-IV & B CA (critical area). The Catawba River chain lakes have
regulated flow from the dams. The minimum flow that has been used in the past WLAs has
been 228.7 cfs.
Existing limits at 7.5 MGD are BODS= 30 mg/1, NH3 monitoring, TSS =30 mg/1, Fecal =
200/ 100m1, monthly monitoring of TN and TP, a phenols limit of 21 ug/l, chronic toxicity limit
of 4.8% in JAN APR JUL OCT. Instream monitoring for DO, fecal, temp and conductivity is
currently required. Fecal and conductivity will be dropped.
Spec limits for expansion to 9.5 and 11.5 MGD, were completed in 1991 and 1998. DWQ
recommended BPJ limits of 15 mg/1 BOD5, 4 mg/1 NH3 and DO > 5 mg/1. May need some
revisions of nitrogenous inputs of direct dischargers into the lake. Chronic tox tests of 6 and
7% would also be recommended.
Preliminary recommendation for 10.5 MGD - BPJ limits of 15/4/5, TRC = 28 ug/1, phenols and
mercury limit, copper, zinc and sulfates monitoring in the NPDES permit, Chronic quarterly
test (CP 6.6%. Continued instream monitoring for temperature and DO. Recommend that
facility conduct TP optimization study for plant because of elevated effluent TP
concentrations.
TOXICITY TESTING:
Current Requirement: Chronic Ceriodaphnia P/F © 4.8%: JAN APR JUL OCT
Recommended Requirement: 1) ® 7.5 MGD - Chronic Ceriodaphnia P/F Q 4.8%; JAN APR JUL
OCT,
2) @ 10.5 MGD - Chronic Ceriodaphnia P/F @ 6.6%; JAN APR JUL OCT
Has consistently PASSed the tox test since July 1996. Two Late tests in 1998. Last FAILs in
April and May 1996.
Town of Valdese WWTP Fact Sheet
NPDES Renewal
Page 1

COMPLIANCE SUMMARY:
Thus far in 2000, Valdese has had one permit exceedence for TSS in March. NOV and
assessment in 6/00 for the violation of TSS and fecal discharge limits. Averages for Qw= 5.4
MGD, BOD5 = 5.0 mg/1, NH3 = 0.35 mg/1, TSS = 22.1 mg/1 , TN = 3.6 mg/1 , TP = 3.8 mg/1.
In 1999, Two exceedences of TSS in June and November. NOV and assessment in 9/99 for the
violation of TSS discharge limits. Averages were Qw = 5.2 MGD, BOD5 =5.8 mg/1, TSS = 26.9
mg/1, and NH3 = 0.23 mg/1, TN = 4.4 mg/1, TP = 5.4 mg/1.
In 1998, One BOD5 violation and 4 TSS violations. NOV and assessment in 7/98 for the
violation of TSS discharge limits. Qw averaged 5.5 MGD, BOD= 7.3 mg/1, TSS = 50 mg/1, NH3
= 0.23 mg/1, TN = 7.4 mg/1, TP = 5.7 mg/1.
In 1997, No exceedences of permit limits. Qw averaged 4.9 MGD, BOD= 3.9 mg/1, TSS = 13.4
mg/1, NH3 = 0.39 mg/1, TN = 6.3 mg/1, TP = 7.4 mg/1
Chlorine values are relatively high, the averages ranged from 0.535 mg/1 to 1.04 mg/1.
Maximum values reported are 1.9 mg/1 to 4.1 mg/1
INSTREAM MONITORING:
Instream monitoring for dissolved oxygen and temperature will be continued. Sites will be
upstream 100 feet of discharge point and downstream 1 mile below the discharge at SR1001.
Instream monitoring for fecal coliform and conductivity will be deleted due to new DWQ policy.
April - October, 1997 - 1999: All data looks good, no instream violations of DO. DO values
range from 8 to 10 mg/1, upstream and downstream. There were no exceedances of the fecal
coliform standard instream. Instream BOD5 averages 2 mg/1.
PROPOSED CHANGES:
The following modifications have been made to the permit:
• The addition of an effluent page for wasteflow of 10.5 MGD based on the facility's
request for expansion due to increased flow from local manufacturing company and
future projected growth.
• Instream monitoring for fecal coliform and conductivity will be deleted due to new
DWQ policy.
• The addition of mercury and sulfates limits at 7.5 MGD and 10.5 MGD based on
reasonable potential analysis of LTMP data.
• The addition of a chromium limit at 10.5 MGD based on reasonable potential analysis
of LTMP data.
• The addition of copper and zinc monitoring based on reasonable potential analysis of
LTMP data.
• Facility must conduct a TP optimization study to determine the sources of high
effluent TP values.
• The addition of a total residual chlorine limit of 28 ug/1 upon expansion to 10.5 MGD.
PROPOSED SCHEDULE FOR PERMIT ISSUANCE:
Draft Permit to Public Notice: 9/27/00
Permit Scheduled to Issue: 11/20/00
STATE CONTACT:
If you have any questions on any of the above information or on the attached permit, please
contact Jackie Nowell at [phone] ext. 512.
DATE:
(0 0/0
Town of Valdese WWTP Fact Sheet
NPDES Renewal
Page 2

03i10i' 1993 02: 38 4 PAGE 02
lr' * u1VAir virriuw.UUMM1 Ni`. Pam/ #Ic . C 4 Ai, 'Le .lr 14 r.7 - .141,LL " T
C'4/1A-ci..,I) 11ltz,'G Ue T6STiA/ 4 /7' in U� c 7'•a rr...#41 #c 1
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/ F'7 f f t • il_A 3 ���i Kf i �ti A /f J f 4dQ r r 1 f 1 r .'1 �� r si.� i .. • �a.fe
if Y A E �.' � i s /I7e k"e di ii AP9,5. /7 z /r» KS/ 4,04-.a . £»'F Tc
t, (I -5 da f would be_ 41e[1essi/A? i c'',.s-1 bl;s1?
1)A.; f, j)« tie 5 1/04 .41 b;/. 0 oft::
r cs .� �"�• ern/o S, ftd.0 a f rre i W0.y I ice. f ,.r• Re do frmpt.,7ixci
NAM
fil_22.WS SUPERVISOR COMMENT:
Nam.
DATE: M — 400
ti
;DATE:(r.V
•
Town of Valdese WWTP Pact Sheet
4PDEfi Renftwril
rT 't-fi'. 1 udU Ol NOI JOBS All itrEi ;11WM W3Q Wild GS 26a oeo2-03-03a

REGIONAL OFFICE COMMENT:
NAME: DATE:
NPDES SUPERVISOR COMMENT:
DATE: / 43*
Town of Valdese ATITP Fact Sheet
NPDES Renewal
Page 3

Catawba River Basin, Subbasin 030831
CTB32
'C(X)48 55
O'141245
546
HISS WIT
l ; -
3
0
3 Miles
• Swi.shp
Husb.shp
•' Usgs98_83.shp
• Npdes6_99.shp
+ Ambst97_83.shp
Majhypl.shp
�v Hydrography
Mb.shp

TOXICANT ANALYSIS
acilityName
ValdeseWWTP
i
NPDES #
NC0041696
Qw(MGD)
7.5
7Q10s (cfs)
229
IWC (%)
4.83
c'ving Stream
Lake Rhodhiss
Stream Class
WS-IV & B CA
FINAL RESULTS_
Chloride
ax. Pred Cw
1022000
ug/
Allowable Cw
5174731.2
ug/
Silver
ax. Pred Cw
9.5
ug/
Allowable Cw
1.2
ugl
Phenols
ax. Pred Cw
74.4
ug/
Allowable Cw
20.7
ug/
Copper
ax. Pred Cw
189
ug/
Allowable Cw
144.9
ug/
Cadmium
ax. Pred Cw
20.4
ug/
Allowable Cw
41.4
ug/
Nickel
ax. Pred Cw
27.3
ug/
Allowable Cw
517.5
ug/
Lead
ax. Pred Cw
27
ug/
Allowable Cw
517.5
ug/
Zinc
ax. Pred Cw
2719.9
ug/
Allowable Cw
1034.9
ugl
Chromium
ax. Pred Cw
823.9
ug/
Allowable Cw
1034.9
ug/
Cyanide
ax. Pred Cw
26.4
ug/
Allowable Cw
103.5
ug/
Mercury
ax. Pred Cw
6.24
ug/
Allowable Cw
0.25
ug/
Sulfates
ax. Pred Cw
17535900
ug/
Allowable Cw
5174731.2
ug/
frLL VYI.I G FC�II 1
L1M H
man IT
Limir
12/12/00

TOXICANT ANALYSIS
Facility Name
Valdese WWTP
NPDES #
NC0041696
Qw (MGD)
10.5
7Q1Os (cfs)
229
/WC (%)
6.64
c'ving Stream
Lake Rhodiss
Stream Class
WS-IV & B CA
FINAL RESULTS
Chloride
ax. Pred Cw
1022400
ug/
Allowable Cw
37677665.1
ug/
Silver
ax. Pred Cw
9.5
ug/
Allowable Cw
0.9
ug/
Phenols
ax. Pred Cw
74.4
ug/
Allowable Cw
15.1
ug/
Copper
ax. Pred Cw
189
ug/
Allowable Cw
105.5
ug/
Cadmium
ax. Pred Cw
20.4
ug/
Allowable Cw
30.1
ug/
ug/
Nickel
ax. Pred Cw
27.3
Allowable Cw
376.8
ug/
ug/
Lead
ax. Pred Cw
27
Allowable Cw
376.8
ug/
Zinc
ax. Pred Cw
2719.9
ugl
Allowable Cw
753.5
ug/
Chromium
ax. Pred Cw
823.9
ug/
Allowable Cw
753.5
ugl
Cyanide
ax. Pred Cw
26.4
ug/
Allowable Cw
75.4
ug/
Mercury
ax. Pred Cw
17.76
ug/
Allowable Cw
0.18
ug/
Sulfates
ax. Pred Cw
17535900
ug/
Allowable Cw
3767,665.1
ugl
444.130Cf .cc tf
CIA Ir
, (t-
itutn (!v%t
12/12/00

TOXICANT ANALYSIS
Chloride
Parameter=
Silver
Parameter= Phenols I
;Parameter=
Co,.:r
E'EAmmeter
250000Aga
Standard=
0.06pgll
Standard. 1 ug4
i .Standard==
=
isisjStandard=
BDL=1/2DLdualData
RESULTS
n3DL=1/2D•tualDataRESULTS
n3DL=1/2DactualDatRESULTS
nBDL=1/2D
ual Da
RESULTS
n
413000
413000
Std Dev.
123M33.38
1
25
<5
Std Dev.
1.15289491
1
5
<10
Std Dev.
7.384595
1
•1
90
Std Dev.
17.322
1
357000
357000
Mean
362555.56
2
25
<5
Mean
2.8125
ii
2
5
<10
Mean
8.790323
2
30
30
Mean
31.944
2
394000
394000
C.V.
0.3407295
3
2.5
<5
C.V.
0.40991819
3
5
<10
C.V.
0.840082
3
27
27
C.V.
0.5423
3
343000
343000
4
2.5
<5
4
5
<10
4
18
18
--
4
324000
324000
5
2.5
<5
5
5
<10
5
24
24
-_
5
541003
541003
Mutt Facto'
1.6
6
2.5
<5
Mutt Factor
1.9
6
5
<10
Mult Factor
2.4
6
29
29
Mutt Facto
®
6
639000
639000
Max. Value
639000
ugll
7
2.5
<5
Max. Value
5
pglt;i
7
5
<10
Max. Value
31
pg/li
7
21
21
Max. Value
90
p• ;
7
350000
350000
Max. Pred l
1022400
mg!
8
2.5
<5
Max. Pred (
9.5
pglf i s i
8
5
<10
Max. Prod (
74.4
pg/l E :
8
50
E0
Max. Pred
189
.
8
295000
295000
Allowable (
5174731.2
pgll
9
2.5
<5
Allowable C
1.2
pg/1 i i
9
5
<10
Allowable C
20.7
pg/l i
9
31
31
Allowable •
144,9
p•
9
318000
318000
10
2.5
<5
iiii
10
5
<10
10
28
28
-_
10
420003
420000I
11
4
<8
11
5
<10
11
26
26
-_
11
466000
466000
12
4
<8
12
5
<10
12
27
27
-
12
332000
332000
13
5
<10
13
5
<10
13
18
18
13
84000
84000
14
1
<2
14
5
<10
14
_j
14
430000
430000
15
1
<2
15
5
<10
15
27
27
-_
15
370000
370000
16
5
17
5
<10
16
26
26
__
E
16
270000
270000
17175
(.9
<10172323
--
17
180003
180003
1818
5
<10
18
25
25
--
18
19
19
5
<10
19
-_-_
19
20
20
5
<10
20
20
21
21
23
23
21
----
E
21
22
22
11
11
22
-
22
23
23
10
10
23
---_
:'
23
24
24
12.3
12.3
24
:i
24
25
25
10.2
10.2
25
-_-_
25
26
26
5
5
26
26
27
27
6
6
27
---_
27
28
28
12
12
28
---_
28
29
29
28
28
29
---_
29
30
30
31
31
30
_--_
30
31
31
24
24
31
31
41' 4%:&,`Att4ct''.w‘
7/24/00

TOXICANT ANALYSIS
Cadmium
Parameter.
Nickel
Parameter=
Lead
Parameter=
Zinc
Parameter=
Chromlur
:;standard =
50
Standard =
25
pgA
Standard=
50
pg/l
2
p9/l
itandard=
25
rrpll
3DL=12D1ctual
Data
RESULTS
niiDL=12D
Actual Data
RESULTS
iin
3DL=12D
4ctual Data
RESULTS
n
9DL=12DL‘ctual
Data
RESULTS
n
3DL 12D
100.7
1
4
1
<2
Std Dev.
1.27347
1
10
10
Std Dev.
2.6892
1
15
15
Std Dev.
2.69471
1
681
68
Std Dev.
2
13
13
Mean
5.4444
2
11
11
Mean
6.44444
2
69
69
Mean
61.278
2
4
1
<2
Mean
1.30556
1.6434
3
4
3
35
35
C.V.
0.4939
3
5
<10
C.V.
0.41814
1
<2
C.V.
0.97543
3
7.5
<15
C.V.
4
5
<10
4
32
32
4
4
4
7.5
<15
1
<2
5
4
5
jil
f tie
5
5
<10
1
<2
5
2.5
<5
5.9
6
4
6
30
Mult Factoil
2.1
6 5
<10
Muh Facto/
1.8
1
<2
Mull Facto
3.4
6
2.5
<5
Mult Factor
13
p9 '
7 5
<10
Max. Value
15
ggif:1 7
27
27
Max. Value
461 pill::: 7
4
1
<2
Max Value
6
ug/I
:: 7
5
<10
Max. Value
2719.9
41: i 8
13
27.3
pg/4
8 5 <10
Max. Pred I
27
p9Ai: 8
35
35
Max Pred (
1
<2
Max Pred
20.4
pg4
?E'- 8
5
<10
Max. Pred
pgA:i 9
45
45
Allowable C
1034.9
pgfri 9
11
517.5
pg/E:
9._ 5
<10
Allowable (
517.5
1 <2
Allowable (
41.4
pgll
:0; 9
5
<10
Allowable C
10 5
<10
10
25
25
10
9
I <2
10
5
<10
11
5
11 5
<10
11
34
34
1 <2 __
11
5
<10
12 5<10
12
17
17
12
107
12
5<10
2<4
13 5<10
13
26
26
13
7.5
6 61
13
5<10
14
3
14
52
52
2.5I<5
14
5<10
14 5<10
15 7.5
<15
15
31
31
15
13
15
5
<10
0.5 <1
16 7.5
<15
16
43
43
16
5.7
0.5 <1
16
5
<10
17
6.2
17 7.5
<15
17
33
33
C 5 <1
17
2.5
<5
18
18 7.5<15
18
40
40
0.5<1
18
2.5<5
19
19
19
19
20
20
20
20
21
21
21
•
21
22
22
22
22
23
23
23
23
24
24
24
24
25
25
25
25
26
26
26
26
27
27
27
27
28
28
28
28
29
29
29
29
30
30
30
30
31
31
31
31

j111+11J'v4
TOXICANT ANALYSIS
t Parameter=I Cyanide
Parameter=
Mercury
I I
I P,Brameter=
Sulfates
pgll R
`,Standard=
250000
pgll
pg4
Standard-
5
pg4
;Standard=
D.012
tctuel Data RESULTS
n
3DL=1/2DActual
Data
RESULTS
n
DL=I/2DActual
1.
RESULTS
n
BDL=II2DIActual
Data
RESULTS
<8 ' Std Dev.
24.63159
1
5
5
Std Dev.
3.22473
1
2.4
2.
td Dev.
0.5558
1
3507000
3507,p00
Std Dev.
951582.8
<0.2
Mean
02778
2
394000
394000
Mean
697647.1
.
<8
Mean
12.25882
2
2.5
<5
Mean
4.85294
2
0.1
3
0.1
<0.2
C.V.
2.0008
3
180000
180000
C.V.
1.363989
<8
C.V.
2.009295
3
10
10
C.V.
0.66449
<8
4
2.5
<5
4
0.3
0.3
4
371000
371 p00
<8
5
9
9
5
0.1
<0.2
5
266000
266 00
.•
<8
Mult Factor
7.7
6
11
11
Mutt Factor
2.4
6
0.1
<0.2
Mutt Factor
7.4
6
372000
372000
Mutt Facto,
5
<8
Max Value
107
pglE
7
7
7
Max. Value
11
pgn
i 7
0.1
<0.2
Max. Value
2.4
pgl
7
262000
262b00
Max Valua
3507000
tr
1 i 8
0.1
<0.2
Max. Pred
17,76
pg4i
8
426000
426900
Max. Pred
17535900
p9Ai
13
Max Pred 1
823.9
pg8
8
2.5
<5
Max. Pred,
26.4
pg/1
11
Allowable C
1034.9
pglti
9
2.5
<5
Allowable C
103.5
4/1
9
0.1
<0.2
Allowable C
0.2
pgni
9
327000
327000
Allowable C
5174731.2
pgA:
9
i
10
2.5
<5
10
0.1
<0.2
10
348000
348000
11
0.1
<0.2
11
33301>0
333000•
<10
11
2.5
<5
2871000
2871900
.
107
12
2.5
<5
12
0.1
<0.2
12
13
0.1
<0.2
13
210000
210000•
<15
13
3
<6
<0.2
14
457000
457000
<6
14
3
<6
14
0.1
13
15
8
8
15
0.1
<0.2
15
691000
691000
5.7
16
1
<2
16
0.1
<0.2
16
353000
353900
62
17
8
8
17
0.1
<0.2
17
492000
492800
18
18
0.8
b.B•
18
19
19
19
20
20
20
21
21
21
22
22
22
23
23
23
24
24
24
25
25
25
26
1
26
26
27
27
27
28
28
28
29
29
29
30
30
30
31
31
31
,
o4irlYM5try
sly
tike
S
7/24/00

NPDES Long Term Monitoring Request Form
Date of Request i!jJ,Q/UO
Facility
NPDES #
Region
Requestor
NG O� S/I 479 (o
Pretreatment A_D Towns- Keyes McGee (ext. 580)
Contact
E-L Towns- Vacant Position
23)
----S-Z Towns- Steve Amigone (ext 592)
Status of
Program 1) the facility has no SIU's and should not have pretreatment language
aPhe facility has (of-ie-ElevelepiRgi a Pretreatment Program
V additional conditions regarding Pretreatment attached or listed below
Flow Permitted Actual
so
% Industrial
% Domestic
A'^d%a / 1/J/,'" 7/Z//0
L
T
M
P
Pollutant
Check List
POC due to
NPDES
Limit
Required
by EPA*
Required by
503 Sludge**
POC due to SIU"'
Site specific POC (Provide Explanation)""
Frequency at
effluent
BOD
\
fa(Ar
if
M
V
TSS
\
i
Q
M
V
NH3
(M)
M- NPDES
Q
M
Arsenic
Q
M
4
Cadmium
q
Q
M
'1
Chromium
-1
Q
M
I
Copper
4
Q
M
Cyanide
yes
0
M
Lead
4
Q
M
\
Mercury
yas
Q
M
Molybdemium
Q
M
4
Nickel
4
C
M
Silver
ycS
C.
M
Selinium
C
M
I
Zinc
J
M
�l
CilloglDF
IM- 5 f 0-roviLE
M
N.,Sut
FA tc=
" „
M
\l
TN
(w)
tt.{ -Ntte5
M
'rP
(tM)
IA, - t'Pu=f
M
pgeNvl+.L
\/
M
M
'Always in the LTMP
"Only in the LTMP if the POTW land applies sludge
"' Only in LTMP while the SIU is connected to the POTW
"" Only in LTMP when the pollutant is a specific concem to the POTW (ie-Chloride to a POTW who accepts Textile waste)
Q= Quarterly
M=Monthly
Comments: P0-1.01 geclE.VES i i1 ASre • o 0 Pirti
CAV/ /16t Ay — W REMAiN iN t-Twt?.
uAlm r Svt�,z�

828 874 5915
a
v1
11
0
ce
J
E
a
0
lfl
J
7
h
Effluent Data 1996 - 2000
Ni Pb ' Zn
Chloride
CN HL
NI-i3-N
NO3+NO2
TKN Phenols
'Total P : Sulfate , BOD 'TES
1995
I
!
- ----
2B Mar I
<0.005
<0.00
<0.008
0.09 0.01 - 0.0-15 0.066 413 j 0.006 T 0.0008
1.08
1.8
2.16 • <0.01 16_ 1
• 3,507 -
29-Au! <0.005 <0.004 0 013
0.03 <0•.01 : <0.01 0.069 357 '.002 0 60• <0.005' <0.0
0.99
ra.60 <0.01 ' 6.28
. 394
3078ep <0.005 <0,002 <0.008 . 0.027
<0.01 : <0.01 ' 0.035 ! 394 0.01 1 <0.002 <0.6
1.74
4.27 <0.010 4.50
` 180
10-Dec . <0.008 <0.002. <0.008 0.018
<0.01
<0.01
0.032 ' 343 <0.005! <0.002 <0.6.
0.24
5.516 ' 0.023 5.85
: 371
18-Dec
1
<0.01
1997
I
-
i
14.0.0002.
1
13-Feh <0.008 0-005 <0.008
0.024 <0.01 ' <0.01
0.461 . 324 0.009 0.24 0.35
I 2.46
<0, 01 • 5.45
! 266 1.39 5
r
06 ay '
i
'•
<0.01
13-May I <0.005
<0.002
<0.008 0.029
<0.01 <0.01 0.030
541
<0_005' <0.0002i 1.01 3,50
6.63
<0.01 9.71
372 7.23 13.33
o8-Aug
<.01
. 12-Au9 <0.005 <0.002.
<0.008 - 0.021
<0.01
• <0015 0.0271 639
0.011 <0.0002
0.33 5.28 -
2.42
<0.01 9.96 !
262 4.23 14
<0.01
_
11-Nov . <0.005 <0.002 0.011 1
0.050 <0.01
. <0.016 ' 0.035 350
<0.005 <0.0002
0.203 3.87
6.81
<0.01 7.67 i
426 2.01 27 33
+
I
1996
I
0.22
13-Feb <0.005 <0.002. 0.009 0.031
0 013 <0.01
0_045 296 <0005' <0.0002
0.46
4.24 <0.01 ' 5.31
327 3.77 14.66
05-May .
!
<0.01 i
.
_06-May
<0.01
<0.002 <0.008. 0.02e
<0.01 0.011 0.025
318 <0.008: <0.0002 0.17
TN=
4.48 <0.01 3.58
f 348 = 6.01 17.33
03-Aug
,
=
1
- <0.01
04-Auu <0.005_ <0.0021 <0.01
0.026 <0.015
<0_01 0.034
420 '-<0.0061
<0.0002 0.2
TN=
5.20 <0.01 6.74
68
333 2.64 -57
04-Nov '
0.011 .
_- _ -
06-tJov , <0.008 <0, 005 0.107 0.027 <0.015
` <0.015 ' 0.017 466
<0.005 0.0002 0.29 TN=
3.36 0.01 5.197
2871 <2 7
1999
�-
•
01-Feb 1
1
<0.01
, Feb <0.005 <0.002
<0.015
_
0.018 ' <0.01 t <0.0 -0.026 332 :<0.005 <0.0002
0.43 • TN=
3.36! <0.01
2.14 '
6.25
210 4.37 6
12-May 1 <0.005 <0.<0.006
0.065 • <0_01
<0.01 • 0,052
• 64 <0.005 <0,0002
0.17 TN=
4.46 : <0.01
457t�2.4; 7
10-Aug
I r
0.0123
I r
1
1 Aug 1 <0.002
<0.001 0.013 0.027 : <0.005
-<.01 0.031
430 <0.002
0.0003
0.25 TN=
6.252
0.0102
6.88
6911 2.771 8
12-Nov
._
'
0.005
16-Nov , <0.002 <0.001 <0.0051 0.026
<0.005 <.01 : 0.043 370• 1 0.007
<0.0002 0.15 ; TN=
4.37 I
0.006 6.96
<1 i 2.3 5
t ;
1i--•
1

°
In
r~
m
Effluent Data 1996 - 2000
Ag
Cd I Cr Cu • Ni
Pb
Zn
I Chkride
CN
I NH3-N
NO3+NO2'
TKNI Phenols ; Total P [Sulfate BOD
TSS
2040
I
!
► 1
1
1
• 07-Feb
1
_
0.012
08-Feb
0.005
.<0.001 0.0067 1 0.023 1 <0.005'
<0.01
0.033
270 0.008 I <0.0002
0.17 TN=
3.1 0.026
"
3.59 353
3.321
5.33
09-Ntay I
!<0,001 0.00621 0.025
' <0.005;
<.0.01
0.04
180 0.006 0.0029
0.43
0.324 !
3.92 t 0.031
=;
4.16
492
2.14.
6
14-May
I
I I
0.024
j
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s • p
For the Town of Valdese, existing data are insufficient to
explain the increase in total phosphorus between years 1994 and
1995 (discussed in attached pages). The Town of Valdese's flow
and total phosphorus concentrations in recent years are as
follows;
Flow (MGD) Total Phosphorus
:ng/1) (Lbs)
1993 4.8 3.65 53037
1994 4.6 3.48 46347
1995 3.8 6.46 70621
1996 4.4 5.7 - 79550
1997 1.9 7.4 110814
1998 5.5 3.7 96171
1999 5:2 5.3 83895
Factors contributing to Valdese's phosphorous increase may
include a change in ORC between 1994 and 1995, solids loss due to
clarifier work, and solids loss associated with i&I.
The new operator failed to maintain sufficient oxygen
concentrations in the aeration basin for a period of time.
Additionally, he still at various times tries to maintain an
anoxic zone within the aeration basin. Low overall dissolved
oxvaen concentrations and anoxic zones may have raised the amount
of o=csohorus discharged during 1995 and subsequently. Certain
organisms release soluble inorganic phosphorus under anaerobic
conditions.
The Town of Valdese rebuilt their secondary clarifiers around
1998. Solids loss associated with the clarifier work may have
contributed to elevated phosphorus levels.
During heavy rainfall the plant frequently experiences loss of
solids. Increased effluent suspended matter would somewhat raise
teal mass of effluent phosphorus.
The City of L= lair's Lower Creek _ t has been under - o ation
and recons ction during r ece. years. Construc ' •n related
operatio = disruptions are elieved to have b .-n responsible f
increa -d phosphorus dis _mrges in year 199 The City enter
into CC around 1997 a • just recently c' pleted upgrade _d
ex.•_n_sion of the tr rnent facility. since completio of
Fall of 1999, e 1 uent phosphor
ve averaged 0.6 mg/1 which wo
osphorus discha e of 4457 pounds.
nstruction in t.
concentrations
total annual
result in a

Catawba Permitting •
• Subject: Catawba Permitting
Date: Fri, 24 Mar 2000 13:01:34 -0500
From: Tom Belnick <[e-mail]>
To: Charles Weaver <[e-mail]>,
Dave Goodrich <[e-mail]>
CC: Tom Belnick <[e-mail]>
Before you start assigning Catawba files to folks, there are some facilities that may require additional
background info noted below. I'll put a copy of this email into those files, to tip off permit writer about
issues to address.
• Color Dischargers- Currently 8 facilities in Color Alliance, plus Newton which did not join. There
will be some language to add in cover letter and possibly permit for these facilities regarding color
study. Charles- I'll give you a hardcopy list of these facilities, and I'm o.k. if you assign them to me.
• Valdese WWTP- At the ESB meeting this week on Lakes James/ Rhodhiss/Hickory, there was
concern about the increasing TP loading from this facility. Although the load does not appear to
impact Lake Rhodhiss, we don't know how much will be exported downstream to Lake Hickory,
since Rhodhiss doesn't appear to be a TP sink. No need for limits, but Coleen thought we should put
something in permit cover letter asking them to evaluate why TP load is increasing; indicate that
there is concern about downstream lake; and possibly have them do TP optimization study. Michele
W. is looking into how much TP is exported from Lake Rhodhiss to Lake Hickory. Forest W. will
have Jim Reid discuss TP situation with facility.
Mailto:[e-mail]
N.0 DENR-DWQ/NPDES Unit
1617 Mail Service Center, Raleigh NC 27699-1617
Work: [phone] ext. 543
Fax: [phone]
I of 1 3/24/00 2:15 PM

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1197 13 A3 /1 %.-.

Town of Valdese WWTP
Residual Chlorine
7010 (CFS)
DESIGN FLOW (MGD)
DESIGN FLOW (CFS)
STREAM STD (UG/L)
UPS BACKGROUND LEVEL (1
IWC (%)
Allowable Concentration (ugi
Fecal Limit
Ratio of 14.1 :1
228.7
10.5
16.275
17.0
0
6.64
255.89
Ammonia as NH3
(summer)
7010 (CFS)
DESIGN FLOW (MGD)
DESIGN FLOW (CFS)
STREAM STD (MG/L)
UPS BACKGROUND LEVEL
IWC (%)
Allowable Concentration (m
Ammonia as NH3
(winter)
7Q10 (CFS)
200/100m1 DESIGN FLOW (MGD)
DESIGN FLOW (CFS)
STREAM STD (MG/L)
UPS BACKGROUND LEVEL
IWC (%)
Allowable Concentration (m
228.7
10.5
16.275
1.0
0.22
6.64
11.96
228.7
10.5
16.275
1.8
0.22
6.64
24.00
NC0041696
9/14/00

Town of Valdese - Meeting with Construction Grants — 7/26/00
Attendees:
Allan Wahab — Valdese's Engineer
Dan Blaisdell — CG
Cecil Madden — CG
Dave Goodrich — NPDES
Jackie Nowell — NPDES
jmn
• Valdese is upgrading and expanding their treatment plant from 7.5 MGD to 10.5
MGD
• An ATC to upgrade for 7.5 MGD, includes some components sized for 10.5 MGD.
However, the aeration equipment is not for 10.5, will need some additional blowers or
a way to get additional air to the tank.
• Most of plant is industrial flow, wants 10.5 MGD in the permit for future industrial
situation.
• Valdese wants permit issued for 10.5 MGD in some conditional way.
• 201 plan has been approved a year ago. First phase of FONSI to go to 10.5
MGD. In the 20-year projection, 10.5 was justified.
• The cost of the upgrade was $5.7M per Cecil Madden.
NPDES recommendations on the permit.
1 The addition of a mercury limit @ 7.5 mgd and 10.5 MGD
2. Will add a supplement page of 10.5 MGD and will include specific areas, such as
influent pump, aeration equipment, plant outfall and solids handling.
3. Will include 80-90% language in the cover letter.
4. Valdese must do a TP optimization study, i.e. identify sources of TP loads, how to
reduce inputs to plant, how to minimize the discharge amounts. No TP limits
recommended at this time.

FILE No. 121 08/30 '00 14:42 ID:THE WOOTEN COMPANY
9198343589
PAGE 1
The
Woolen
Company
Engineering
Planning
Architect ore
--1INMEN.01.•
120 N. Boylan Avenue
rizleign. KC
27603
919.828.0531
Since 1936
FAX COVER SHEET
TO: tee`Qw C
ATTN: r\ Fax Number:
FROM:
Fax Number:
-3 589
U r - 2000
RE: 1_ C goPt-il vJ c JOB NO. Z7
tAcriir1C:AT7ohl.
N'UMJ3LR OF PAGES TO FOLLOW:
SPECIAL INSTRUCTIONS:
If you do not receive this FAX clearly, or have any questions, please tali
919-828-0531.
Transmitted By:
Date: 5
Time:

FILE No. 121 08/30 '00 14:42 ID:THE IOOTEN COMPANY 9198343589
PAGE 2
VALDESE
MANUFACTURING COMPANY
A DIVISION OF MZR1DIAN jNgus'n 1Es, INC.
July 23, 1998
Mr. Jeffrey V. Morse, Manager
Town of Valdese
PO Box 339
Valdese, NC 28690
Re: Reserve Wastewater C pacity
Valdese Mfg.
Dear Mr. Morse:
Valdese Mfg Inc. currently has a Town of Valdese permitted capacity of 1 mad reserved in the Town's
Wastewater Treatment Plant.
According to our discussions, the Town is lathe planning stages,Qf expanding Its Wastewater Treatment
Plant and needs to include any planned expansion by Valdese Mfg. Based on our current projections, the
company expects to expand our operation in the next 5 to seven years by .5 mgd Therefore,. It is requested
that .5 mgd additional capacity be included in the proposed expansion and reserved for Valdese Mfg.
If additional information is needed, please advise.
Sincerely
7.e/dr%,t_
Tim Slddmore
Plant Engineer
CORPORATE OFFICE: P.O. DRAMA 10 VALPESlr, N.C. 28890-0010 704-874.2151 FAX [phone]
1359 BROADWAY, 8U1'CE 806 NEW YORK, N.Y. 10018 212.967-5970 FAX [phone]

Town of Valdese
• Subject: Town of Valdese
Date: Thu, 14 Sep 2000 07:30:40 -0400
From: Mike Myers <[e-mail]>
To: Jackie Nowell <[e-mail]>
After receiving an Authorization to Construct from the Division of Water
Quality, construct and operate additional wastewater treatment
facilities and upgrade the existing influent pump station, aeration
equipment (including additional aeration), plant outfall, and residuals
management facilities. The ultimate design capacity after expansion and
modification to existing facilities shall be 10.5 MGD, and
Michael J. Myers
Environmental Engineer
NPDES Unit - Division of Water Quality
1617 Mail Service Center
Raleigh, NC 27669-1617
[phone] x508
mailto:[e-mail]
Michael J. Myers [e-mail]>
Environmental Engineer
NC DENR DWQ
NPDES Unit
1 of 1 9/14/00 8:35 AM

UPGRADE AND EXPAND THE EXISTING
WASTEWATER TREATMENT FACILITIES
VALDESE, NORTH CAROLINA
AGENCY: NORTH CAROLINA DEPARTMENT OF ENVIRONMENT
AND NATURAL RESOURCES
CONTACT: JOHN R. BLOWE, P.E., CHIEF
DENR - DIVISION OF WATER QUALITY
CONSTRUCTION GRANTS AND LOANS SECTION
1633 MAIL SERVICE CENTER
RALEIGH, NORTH CAROLINA 27699-1633
September 17, 1999

FINDING OF NO SIGNIFICANT IMPACT (FNSI)
Title VI of the amended Clean Water Act requires the review and approval of environmental
information prior to the construction of publicly -owned wastewater treatment facilities
financed by the State Revolving Fund (SRF). The proposed project has been evaluated for
compliance with the North Carolina Environmental Policy Act and determined to be a major
agency action which will affect the environment.
Project Applicant: Valdese, North Carolina
Project Number: CS370396-07
Project Description: The proposed project consists of upgrading and expanding the existing
7.5 mgd plant to a 10.5 mgd treatment facility.
Total Project Cost: $5,766 315
Revolving Loan Amount: $S,116 315
Appalachian Regional Council: $ 200,000
CDBG: $ 450,000
Mitigative measures will be implemented to avoid significant adverse environmental impacts,
and an environmental impact st4tement (EIS) will not be required. The decision was based on
information in the facilities plan,, a public hearing document, and reviews by governmental
agencies. An environmental assessment supporting this action is attached. This FNSI
completes the environmental review record, which is available for inspection at the State
Clearinghouse.
No administrative action will be taken on the proposed project for at least thirty calendar days
after the FNSI has been published in the North Carolina Environmental Bulletin.
Sincerely,
Kerr TC$tevens, Director
Division of Water Quality

ENVIRONMENTAL ASSESSMENT
A. Proposed Facilities and Actions
Figure 1 identifies the site of the proposed improvements to the existing wastewater treatment
facilities.
Treatment Facilities. The existing 7.5 mgd treatment plant will be upgraded and expanded to
a 10.5 mgd treatment facility. Improvements to the existing plant consist of replacing the
existing bar screen and the grit removal system, modifying the influent pump station, and
upgrading the primary clarifiers. Additional improvements consist of new anoxic selector
tanks, a secondary clarifier, expanding the chlorine contact tank; and adding dechiorination
equipment. Upgrading the treatment plant will require providing diffused aeration and
supernatant decantfacilities in an existing sludge holding tank and rebuilding the existing
centrifuges. Additional requirements will consist of yard piping, site grading, and electrical
work. The effluent will continue to be discharged into the Catawba River. The sludge will
continue to be composted and provided to the public as a soil amendment or conditioner.
B. Existing Environment
Topography and Soils. The town of Valdese is located in Burke County. The topography
ranges from approximately 1,000. feet above mean sea level in the northeast section of the area
to 1.843 feet above mean sea level in the southwest section. The dominant soil association is
Pacolet-Cecil. Soils are generally very deep and well drained with clay subsoils.
Surface Waters. The service area is located in the Catawba River Basin. The effluent from
the town of Valdese's wastewater treatment plant is discharged into the Lake Rhodhiss section
of the Catawba River. An analysis of water quality in Lake Rhodhiss indicates there is
significant nutrient loading from agricultural runoff, urban stormwater, and effluent discharges
from wastewater treatment plants. The Catawba River Basin Management Plan has been
developed to reduce the loading to the nutrient enriched waters in the Catawba River Basin.
Water Supply. The town of Valdese's water supply comes from the impounded Lake
Rhodhiss section of the Catawba River. The effluent from the wastewater treatment plant is
discharged downstream of the water supply intake point.
C. Existing Wastewater Facilities
The town of Valdese operates a 7.5 mgd wastewater treatment plant with the effluent
discharged into the Lake Rhodhiss section of the Catawba River. The existing plant was
constructed in 1983, and several modifications occurred in subsequent years. Major treatment
processes/components consist of mechanical screening, aerated grit removal, influent pumping,
primary clarification, extended activated sludge system. secondary clarification. chlorine
disinfection. gravity sludge thickening, sludge dewatering by centrifuge. and aerated static pile

sludge composting. The existing wastewater treatment plant is operating at approximately 67
percent of the design capacity. Approximately 83 percent of the total flow entering the
wastewater treatment plant comes from commercial, institutional, and industrial users. In
addition to providing central collection and treatment service for all of the approximately 4,200
Valdese residents, the town also provides wastewater treatment service for eastern Burke
County and Rutherford College. The town of Valdese also processes a portion of the flows
from the towns of Connelly Springs, Drexel, and Hildebran. An analysis of the flows indicated
that infiltration and inflow (I/I) were non -excessive according to the rating criteria. However,
the treatment plant experiences high flows during significant rainfall events, and a sewer
rehabilitation program will continue to identify and remove excessive amounts of inflow
entering the collection system.
D. Need for Proposed Facilities and Actions
The town of Valdese operates a 7.5 mgd wastewater treatment plant in which some of the
equipment is too deficient to maintain consistent compliance with the parameters of the
NPDES permit. The existing effluent limitations are BOD5=30 mg/1. TSS=30 mg/1, Fecal
Coliform=200/100 ml. and pH=6.0-9.0 SU. The town desires to expand the existing treatment
plant to serve the future needs of a growing service area. Additionally, the treatment plant
needs to be upgraded to comply with the Catawba River Basin Management Plan. Speculative
effluent limitations for the proposed 10.5 mgd treatment plant are BOD5=15 ma/1, TSS=30
mall. Fecal Coliform=200/100 ml. NH3-N=- mall, Dissolved Oxygen=5 mg/1, Residual
Chlorine=17 Aug/1, and pH=6.0-9 0 SU. In addition to the need to provide more stringent
treatment to protect nutrient enriched waters in the Catawba River Basin, the proposed facilities
will also be upgraded and expanded to produce compost that can be distributed to the public for
beneficial uses.
E. Alternatives Analysis
The town of Valdese needs tomake significant improvements to the existing wastewater
treatment facilities to process future flows. to achieve more stringent effluent limitations, and
to comply with the requirements of 40 CFR, Part 503. Accordingly, a facilities plan was
prepared, and several alternatives were evaluated. The "no -action" alternative was determined
not to be practical due to the inability of the existing plant to process the projected hydraulic
flow, comply with stringent effluent limitations. and protect water quality in the Catawba River
Basin. An optimum plant operation will not achieve the desired results because additional
treatment capacity is required. and the existing treatment facilities do not have the capability to
consistently comply with the future effluent limitations. A land application system was
determined not to be the most feasible solution for solving the wastewater treatment problems.
The existing treatment plant has some deficient equipment that can be repaired or upgraded,
and adequate space is available to add new facilities to process the projected flow for the
future. This alternative has the lowest present -worth value. and it is the selected alternative.

F. Environmental Consequences, Mitigative Measures
All of the proposed improvements will take place at the existing treatment plant site. The site
has been previously cleared, and is well isolated from residential areas. None of the proposed
facilities will be located in a wetland or floodplain area. A sedimentation and erosion control
plan will be implemented to control adverse runoff to streams. The Department of Cultural
Resources is not aware of any properties of architectural, historical, or archaeological
significance that would be affected by the project. North Carolina's Wildlife Resources
Commission does not object to the proposed project. The U.S. Fish and Wildlife Service
evaluated the proposed plan and requested additional information to make an assessment about
the potential impact of direct and secondary effects to fish and wildlife resources. Additional
information was provided, and.the_Service has determined that the proposed project will not
affect endangered or threatened species. The Service has stipulated that obligations under
Section 7 of the Endangered and Threatened Species Act must be reconsidered if 1) new
information reveals that the proposed action may affect listed species or critical habitats in a
manner that were not previously considered. 2) the proposed action is subsequently modified in
a manner that was not considered in the review. or 3) a new species is listed or critical habitat is
determined that may be affected by the proposed action. The Service also encourages the town
of Valdese to ensure that measures such as the Zoning Ordinance and the Watershed
Protection Ordinance be implemented to ensure long-term protection of riparian areas. The
Service has further requested the town to voluntarily encourage the protection of riparian
buffers along all watercourses If to minimize the effects of wildlife habitat fragmentation. 2) to
improve streambank stability, 3) to reduce stormwater runoff and 4) to improve water quality.
G. Public Participation, Sources Consulted
A public hearing was held January 11, 1999 on the proposed project to upgrade and expand the
wastewater treatment plant. No opposition to the proposed project has been expressed. A
resolution was passed by the town council to implement the proposed project. A Valdese
customer using 5,000 gallons of water currently pays $8.08 per month for sewer service. The
proposed project will result in a typical customer paying approximately $9.35 per month for
sewer service.

Sources consulted about this project for information or concurrence included:
1) Town of Valdese
2) North Carolina Department of Environment and Natural Resources
-Wildlife Resources Commission
-Division of Parks and Recreation
-Division of Air Quality
-Groundwater Section
-Division of Environmental Health
-Water Quality Section
-Division of Pollution Prevention & Environmental Assistance
-Division of Forest Resources
-Asheville Regional Office
-Legislative and Intergovernmental Affairs
3) North Carolina Department of Cultural Resources
4) North Carolina State Clearinghouse
5) U.S. Fish and Wildlife Service

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• — agnPOSE'? ':"•r A STE A ER IMPROVEMENT`-

ENGINEERING NARRATIVE IN SUPPORT OF REQUEST FOR
MODIFICATION OF NPDES PERMIT NO. NC0041696
TOWN OF VALDESE
BURKE COUNTY, NORTH CAROLINA
This application package is being submitted on behalf of the Town of Valdese in request for
amendment of NPDES Permit No. NC0041696 issued for the operation of the Lake Rhodhiss
Wastewater Treatment Plant. The current NPDES Permit for 7.5 MGD expired May 31, 2000 and
the Town submitted a request for renewal of subject permit in November 1999. The Town is
awaiting response on their November 1999 renewal request from the Division of Water Quality.
This modification is being requested to increase the capacity of the treatment plant from 7.5 to
10.5 MGD. An increase in plant capacity is needed to accommodate 500,000 gallons per day of
additional wastewater expected from the Valdese Manufacturing Company and to handle future
wastewater treatment needs of anticipated residential, commercial, and industrial growth in the
Valdese portion of the regional Burke County 201 Facilities Planning Area.
The Lake Rhodhiss Wastewater Treatment Plant was constructed in 1983 to provide secondary
treatment for an average daily flow of 7.5 MGD with BODS and TSS concentrations of 300 mg/1
and 200 mg/1, respectively. This facility serves 5 municipalities including eastern Burke County,
with a total population of approximately 13,430 persons, and 10 Significant Industrial Users.
Effluent limitations established in the NPDES Permit (No. NC0041696) for the plant discharge
into the Catawba River are summarized in Table 1. The unit operations/processes at the plant
include mechanical screening, aerated grit removal, influent wastewater pumping, primary
clarification, extended aeration type activated sludge system, chlorine disinfection, gravity sludge
thickening, sludge dewatering by centrifuge, aerated static pile sludge composting, and influent
and effluent flow metering. Composted sludge is given away to the public as a final disposal
method. Detailed design data for the plant are given in Table 1.
The upgrading and expansion of the Lake Rhodhiss Wastewater Treatment Plant by -in -large
involves the replacement of the existing equipment that is in deteriorated conditions, upgrading
equipment within the existing treatment structures and the addition of new facilities. The expansion
of the treatment plant is primarily to accommodate the requested reserve wastewater treatment
capacity by the existing textile industries in the Town of Valdese. The Town requested an
Authorization to Construct (ATC) from the Construction Grants & Loans Section (CG&L) for
expansion of the existing 7.5 MGD WWTP to 10.5 MGD. The ATC submittal included the
provision of new anoxic selector tanks, 110' diameter secondary clarifier and RAS/WAS pump
station and the expansion of the existing chlorine contact tanks to handle the expanded plant
capacity to 10.5 MGD. However, the ATC was only issued for the upgrade of the 7.5 MGD
facility and not the 10.5 MGD expansion. CG&L required that the following items be addressed
before an authorization to expand to 10.5 MGD could be granted:
1. Modification of the current 7.5 MGD NPDES permit to 10.5 MGD.
2. Provision of additional influent pumping capacity.
3 . Provision of additional aeration capacity in the aeration basins.
4. Provision of additional effluent outfall capacity.
5. Expansion of the sludge composting facilities.
Page 3 of 25

Lake Rhodhiss WWTP
Valdese, North Carolina
NPDES No. NC0041696
In an effort to keep construction costs down, the Town has elected to construct items 2 through
5 above at a later time and proceed with the remainder of the plant upgrade and expansion as
approved in the ATC. It should be noted that the 201 Facilities Plan was approved by the State for
a 10.5 MGD expansion with stipulated conditions of expansion of the influent pumping capacity,
aeration facilities, composting facilities and effluent outfall capacity at a later date (i.e prior to
exceeding the present permitted flow of 7.5 MGD). Flow projections for the Town of Valdese
service area indicate that the plant will reach the average daily flow capacity of 7.5 MGD in the year
2008. This means that in the year 2007 the plans and specifications for the above mentioned future
improvements will have to be submitted to the State for approval and the construction of the said
improvements will have to be completed in the year 2008. In consideration that expansion of the
influent pumping capacity, aeration capacity in the aeration basins, effluent outfall capacity and
sludge composting facilities will take place at a future date, it is requested that the new NPDES
Permit be issued with effluent limitations for flows of 7.5 MGD and 10.5 MGD respectively. For
10.5 MGD flow the NPDES Permit will include the following stipulated conditions:
1. When the plant average daily flow reaches 6.75 MGD (90% of 7.5 MGD) flow, the
Town shall prepare and submit the plans and specifications for expansion of the
influent pumping capacity, aeration capacity, sludge composting facilities, and
effluent outfall capacity to handle the average and peak daily flows of 10.5 MGD and
26.25 MGD, respectively.
2. Receive Authorization to Construct for proposed improvements outlined in item 1
above within six months following submission of plans and specifications and
advertise for bids.
3. Complete construction within 12 months after the issuance of the Notice to Proceed.
4. Achieve compliance with the effluent limitations set forth in the 10.5 MGD NPDES
Permit within six months after the completion of construction.
The proposed improvements (Figure 1) approved in the ATC are described as follows:
1. Provide a headworks by-pass structure with 1 1/4-inch manually cleaned bar screen.
Replace the existing deteriorated mechanical screens and screenings conveyor with
new screens with 3/8" screen opening and a new double hopper screenings
compactor. The screens with smaller openings are needed to avoid pump and sludge
line clogging and to enhance and improve quality of the biosolids compost product.
2. Replace the existing grit removal equipment with grit equipment of stainless steel
construction.
3. Provide new pump control panel for the four existing influent pumps. The new pump
controls will include two variable speed drives for the two 12-inch pumps and
improved operating conditions for all pumps for improved overall plant performance.
Replace motors of the existing 12-inch pumps for operating compatibility with
variable frequency drives. Also, replace the impeller wear rings and bearings of both
the 12-inch pumps.
Page 4 of 25

Lake Rhodhiss WWTP
Valdese, North Carolina
NPDES No. NC0041696
4. Replace drive unit of the primary clarifier no.2. Remove the existing turbine drives
(flocculation drives) from primary clarifier no. 2. Also, install a new 20 ft. diameter
feedwell in primary clarifier no. 2. Sandblast and paint access bridge supports, drive
mechanisms, and scraper mechanisms of both the primary clarifiers.
5. Provide anoxic selector tanks (designed to provide 1.5 hr. hydraulic retention time of
average daily flow of 10.5 MGD) upstream of the aeration basins for selectively
limiting the growth of filamentous organisms and subsequent controlling sludge
bulking. The anoxic selector tanks will also help remove nutrients from the
wastewater. the splitter box and the anoxic tanks will be handled as an alternate bid. A
decision for construction of those items will be contingent upon the project bid cost
and availability of funds.
6. Provide new reduced voltage (soft start) starters for all of the existing 100 Hp
platform mounted aerators (six total) in the aeration basins.
7. Provide an influent splitter box for the secondary clarifiers.
8. Provide density current baffles in the existing two (2) - 110 ft. diameter secondary
clarifiers for improved performance. Also correct leakage along the effluent weirs of
both the clarifiers. Provide one (1) new 110 ft. diameter secondary clarifier to handle
the expanded plant capacity of 10.5 MGD. The new clarifier will be handled as an
alternate bid and a decision for construction of this item will be contingent upon the
project bid cost and the availability of funds.
9. Provide a new submersible RAS/WAS Scum pump station equipped with two 2,625
gpm capacity sludge recirculation pumps, two 400 gpm capacity WAS/Scum pumps
and necessary controls for the RAS/WAS/Scum pumps. Each RAS pump will be
equipped with a manually adjusted variable frequency drive. The new RAS/WAS
pump station will be handled as an alternate bid and a decision for construction of this
item will be contingent upon the project bid cost and the availability of funds.
10. Expand the chlorine contact tanks to handle the design average daily flow of 10.5
MGD. Provide new chlorine residual analyzer and pace the chlorinators with effluent
flow and total chlorine residual analyzer. Provide new chlorine gas leak detector and
cylinder scales for the chlorination system.
11. Provide sulfur dioxide storage and feed facilities, and controls for dechlorination of
chlorine contact effluent prior to discharge.
12. Provide diffused aeration system in the unaerated sludge holding/thickening tank
(existing gravity sludge thickener). Provide supernatant decant facilities in both
aerated holding/thickening tanks (modified existing gravity sludge thickeners).
Remove all unnecessary super structure from the tanks.
13. Provide a new polymer feed system capable of using dry or liquid emulsion type
polymer for dewatering of gravity thickened combined primary and waste activated
sludge by the existing centrifuges.
Page 5 of 25

Lake Rhodhiss WWTP
Valdese, North Carolina
NPDES No. NC0041696
14. Rebuild both the existing centrifuges to high solids centrifuges technology and bid
this item as an alternate. The decision for rebuilding the centrifuges will be contingent
upon the project bid cost and the availability of funds.
15. Provide new surge protection devices for all existing control panels. Provide a new
computer monitoring (SCADA) system. Provide a new standby generator and
automatic transfer switch for the influent pump station and headworks. The existing
standby generator will serve the remaining unit operations/processes at the plant.
16. Upgrade water supply system to supply 2-inch hydrants at locations necessary to
perform good housekeeping and maintenance work.
Construction of the above improvements is scheduled to begin this fall and be completed by the
spring of 2002.
Page 6 of 25

TABLE-1
DESIGN DATA OF THE LAKE RHODHISS WASTEWATER TREATMENT PLANT
VALDESE, NORTH CAROLINA
NPDES PERMIT NO. NC0041696
Design Wastewater Characteristics
Average daily flow, mgd 7.5
Maximum daily flow, mgd 15
Peak daily flow, mgd 18.75
BOD5 (Biochemical Oxygen Demand, 5 day at 20° C), mg/L 300
TSS (Total Suspended Solids), mg/L 200
NH3-N (Ammonia Nitrogen), mg/L 20
Total Phosphorus as P, mg/L 13
Effluent Limitations (NPDES Permit No. NC0041696)
Parameters
Monthly Avg. Weekly Avg.
Flow, mgd 7.5
BOD, 5 day, 20° C, mg/L 30 45
Total Suspended Residue, mg/L 30 45
NH3-N, mg/L -- --
Fecal Coliform (geometric mean, #/100 mL 200 400
D.O. Mg/L -- --
pH, Standard Units 6.0 - 9.0 6.0 - 9.0
Total Nitrogen (NO2+NO3+TKN), mg/L
Total Phosphorus as P, mg,L
Phenol, ug/L 21 (Daily maximum)
Chronic Toxicity PASS/FAIL at 4.8% (Quarterly)
Mechanical Screening
Mechanical Screens:
Number of units, vertical self-cleaning type 2
Unit capacity, mgd, each 18
Channel width, inch 48
Bar (3/8" x 2 1/4" size) spacing, inch c/c 1'/8
Screen opening, inch 0.75
Drive horsepower, hp 1
Electrical service 460 Volts, 3 Phase, 60 Hertz
Accessories: Timer, Shear pin overload, discharge chutes and control panel
Screening Coveyor:
Number of unit, continuous belt type 1
Unit capacity, cu ft/hr 200
Belt width, ft 2
Belt speed; fpm, maximum 100
Drive horsepower, hp 1
Electrical service 460 Volts, 3 Phase, 60 Hertz
Accessories: Timer, sheur pin overload, discharge chutes and control panel
Page 7 of 25

Lake Rhodhiss WWTP
Valdese, North Carolina TABLE-1
NPDES No. NC0041696 (continued)
Aerated Grit Removal System
Grit Chamber:
Number of units 2
Unit capacity, mgd, each 15
Channel width, ft. 5
Channel length, ft. 42
Grit Collector:
Number of units, chain and bucket type 2
Unit capacity, cu ft/hr., each at 10 fpm, maximum 12
Collector speed, fpm 10
Drive horsepower, hp 3/4
Electrical service: 460 Volt, 3 Phase, 60 Hertz
Accessories: Timer, shear pin overload, discharge chutes and control panel
Grit Conveyor:
Number of units, continuous belt type 1
Unit capacity, cu ft./hr 200
Belt width, ft. 2
Belt speed, fpm, maximum 100
Electrical service 460 Volt, 3 Phase, 60 Hertz
Accessories: Timer, shear pin overload, discharge chutes and control panel
Influent Pumps
12-inch Pumps:
Number of pumps, vertical, non -clog, centrifugal type two speed 2
Pump capacity, gpm, each at 700 rpm, 75 ft. TDH 3,000
at 880 rpm, 80.5 ft. TDH 6,800
Drive horsepower, hp, each at 700 rpm, 75% eff. 125
at 880 rpm, 80% eff. 200
Impeller (2 vane type) size, inch, each 23 3/4
Solids size pass through capacity, inch, maximum 5
Electrical service: 460 Volts, 3 Phase, 60 Hertz
Accessories: Overload protection and automatic operation by bubbler level control system
16-inch Pumps:
Number of pumps, vertical, non -clog, centrifugal type 2
Pump capacity, gpm, each 585 rpm, 81 ft. TDH 7,200
Drive horsepower, hp, each at 585 rpm, 81% eff. 200
Impeller (2-Vane type) size, inch, each 30 1/4
Solids size pass through capacity, inch, maximum 6 3/4
Electrical service 460 Volts, 3 Phase, 60 Hertz
Accessories: Overload protection and automatic operation by bubbler level control system
Page 8 of 25

Lake Rhodhiss WWTP
Valdese, North Carolina
NPDES No. NC0041696
TABLE-1
(continued)
Primary Clarifiers
Number of units, 100 ft. Diam. x 13 ft SWD, each
Type
Unit volume, gal., each
Total volume, gal
Hydraulic retention time, hr, at avg. daily flow of 7.5 mgd
at max. daily flow of 15.0 mgd
at peak daily flow of 18.75 mgd
Unit surface area, sq. ft.7,850
Total surface area, sq. ft.
Surface overflow rate, gpd/sq ft. at ave. daily flow of 7.5 mgd
at max. daily flow of 15.0 mgd
at peak daily flow of 18.75 mgd
Unit weir length, ft.
Total weir length, ft.
Weir loading rate, gpd/LF
at ave. daily flow of 7.5 mgd
at max. daily flow of 15.0 mgd
at peak daily flow of 18.75 mgd
Rake drive horsepower, hp, each 3:1 variable speed
Number of turbine, each unit
Turbine recirculation capacity, mgd
Turbine tip speed, fps, maximum
Turbine drive horsepower, hp, each 5:1 variable speed
Reaction well hydraulic retention time, min., minimum
Electrical service
Accessories: FRP weir plate and scum baffle, scum removal and torque
overloadprotection and alarm
Note: The primary clarifiers were designed to be used as reactor clarifiers.
The reaction well and turbines are removed from one of the clarifiers
and at present both clarifiers are used for conventional primary clari-
fication.
2
Solid contact, reactor type
763,334
1,526,668
4.88
2.44
1.95
15,700
478
955
1,194
314
628
11,942
23,884
29,856
2
2
12
4
3
20
460 Volt, 3 Phase, 60 Cycle
Primary Sludge/Scum Pumps:
Primary Sludge Pumps:
Number of pumps, horizontal, induced flow dry pit type 2
Pump capacity, gpm, each at 1,430 rpm, 65 ft TDH 175
at 780 rpm, 18.5 ft TDH 300
Drive horsepower, hp, at 1,430 rpm, 30% eff. 10
at 780 rpm, 43% eff. 2.5
Drive type 4:1 varidrive with adjustable steps
Impeller (recessed) size, inch 10
Electrical service 460 Volt, 3 Phase, 60 Hertz
Accessories: Timer controls, low level cut-off switch and overload protection.
Page 9 of 25

Lake Rhodhiss WWTP
Valdese, North Carolina TABLE-1
NPDES No. NC0041696 (continued)
Scum Pumps
Number of pump, horizontal, induced flow, dry pit type 1
Pump capacity, gpm, at 1,430 rpm, 65 ft TDH 175
at 78 rpm, 18.5 ft TDH 300
Drive horsepower, hp, at 1,430 rpm, 30% eff 10
at 780 rpm, 43% eff 2.5
Drive type 4:1 varidrive with adjustable steps
Impeller (recessed) size, inch 10
Electrical service 460 Volt, 3 Phase, 60 Hertz
Accessories: Timer controls, low level cut-off switch and overload protection.
Aeration Basins:
Number of basins 2
Basin volume, gal., each 1,990,000
Total basin volume, gal. 3,980,000
Hydraulic retention time, hr., at avg. Daily flow 12.74
Number of 100-hp aerators in each basin 3
Total number of 100-hp aerators 6
Total installed aeration horsepower, hp 600
Aerator oxygen transfer capacity, lb 02/hp/hr at standard conditions 3.2
Total installed aeration capacity, hp/1,000 cu ft 1.127
hp/mil. Gallon 150.75
lb 02/hr 1,920
Electrical service 460 Volt, 3 Phase, 60 Hertz
Secondary Clarifiers:
Number of unit, 110 ft diam. x 14 ft SWD, each 2
Type Center feed
Unit volume, gal 994,683
Total volume, gal 1,989,366
Hydraulic retention time, hr, at avg. daily flow 6.36
Unit surface area, sq ft 9,498.5
Total surface area, sq ft 18,997
Surface overflow, gpd/sq ft, at avg. Daily flow 395
Unit weir length, LF 345.4
Total weir length, LF 690.8
Weir overflow rate, gpd/LF, at avg. Daily flow 10,857
Rake drive horsepower, hp 1
Electrical service 460 Volt, 3 Phase, 60 Hertz
Accessories: FRP weir plate and scum baffle, scum removal and overload protection and
alarm.
Sludge Recycle Pumps:
Number of pumps, vertical, non -clog, centrifugal 2
Page 10 of 25

Lake Rhodhiss WWTP
Valdese, North Carolina
NPDES No. NC0041696
TABLE-1
(continued)
Pump capacity, gpm, each
Two pump capacity, gpm,
Drive horsepower, hp, each
at 228 rpm, 8 ft TDH
at 355 rpm, 16.5 ft TDH
at 355 rpm, 20.0 ft, TDH
at 228 rpm, 80% eff.
at 355 rpm, 81% eff.
Electrical service 460 Volt, 3 Phase, 60 Hertz
Accessories: Varidrive with adjustable stops, low level cut off switch and alarm.
Waste Sludge/Scum Pumps:
Number of pumps, vertical, induced flow type, two speed
Pump capacity, gpm, each at 880 rpm, 21 ft TDH(')
at 1,180 rpm, 41 ft TDH (2)
Bath pump capacity, gpm at 1,180 rpm, 30 ft TDH a)
Drive horsepower, hp, each at 880 rpm, 38% eff.
at 1,180 rpm, 33% eff.
at 1,180 rpm, 38% eff. (3)
Electrical service 460 Volt, 3 Phase, 60
Accessories: Timer, low level cut off switch and alarm.
(>) for sludge/scum pumping to primary clarifiers
(2) for sludge/scum pumping to thickeners
(3) for sludge/scum pumping to primary clarifiers by two pumps
Sludge Thickeners
Number of units, 60 ft.diam. x 12 ft SWD
Unit surface area, sq ft
Total surface area, sq ft
Hydraulic loading rate, gpd/sq ft
Solids loading site
Drive horsepower, hp, each
Rake lift drive horsepower, hp, each
Electrical service
Accessories: Automatic control for rake lift and torque overload protection.
Note: One of the sludge thickener is converted to be used as aerated sludge
holidng/thickening tank.
Centrifugal Feed Pumps
Number of pumps, progressive cavity type
Pump capacity, gpm, each, minimum at 20 psi TDH
maximum at 40 psi TDH
Drive (5:1 varidrive) horsepower, hp, each
Electrical service
Accessories: RPM/gpm tachometers, remote electric speed controls on drives.
2,800
5,250
4,100
7.5
30
2
500
400
1,000
7.5
13.5
25
Hertz
Page 11 of 25
2
2,826
5,652
42.5
8.5
3
2
460 Volt, 3 Phase, 60 Hertz
2
50
250
20
460 Volt, 3 Phase, 60 Hertz

Lake Rhodhiss WWTP
Valdese, North Carolina TABLE-1
NPDES No. NC0041696 (continued)
Centrifuges
Number of centrifuges, horizontal, solid bowl type 2
Hydraulic capacity, gpm, each 115
Solids capacity, lb/hr 8,500
Feed solids concentration, % dry wt basis, combined lime - biological sludge 10-14
Solids recovery, percent, no polymer addition 60
2.51b polymer/dry ton, maximum 95
Discharge Cake solids, percent, minimum, no polymer addition 25
Drive horsepower, hp each at 1,800 rpm 150
Electrical service 460 Volt, 3 Phase, 60 Hertz
Accessories: Control panel, lube oil pump, safety shutdown, fault protection system
Aerated Static Pile Composting
Total composting area, sq ft 116,760
Active compost area, sq ft 26,400
Bulking agent (wood chip): dewatered sludge ratio 3:1
Composting period, days 21
Curing period, days 30
Number of aeration blowers 4
Aeration blower capacity, cfm at 3,450 rpm 335
Page 12 of 25

Sulfur Dioxide
Feed System
Effluent
Chlorine
Contact Tank
Chlorine
7 Feed System
(10.5 MGD)
Composting Area Drainage
Thickener _ Gravity
Overflow / Thickeners
Sludge
Dewatering
Building
Influent
Pump Station
Grit Removal
System
Mechanical
Screening
lk (10.5 MGD)
Raw Wastewater
(0.141 MGD TOTAL)
Primary Sludge/
Scum Pump Station
(5.25 MGD)
fl►.
(10.5 MGD)
Secondary
Clarifiers
•
Waste Sludge
(7 MGD ea.)
Primary
Clarifiers
(21.0 MGD) •
� T
SB
(5.25 MGD)
(• Denotes Influent Flow + RAS Flow)
\-411-- --
Sludge Recirculation/ __--
Waste Pump Station
FIGURE 1
TOWN OF VALDESE
LAKE RHODHISS WASTEWATER
TREATMENT PLANT IMPROVEMENTS
SCHEMATIC FLOW DIAGRAM
NPDES NO. NC0041696
(7.0 MGD)
Secondary
Clarifier
r-
Anoxic Tank
(21.0 MGD) •
J
I
(10.5 MGD)
Anoxic SB
(10.5 MGD)
Anoxic Tank
RAS/ WAS
Pump Station
LEGEND
Wastewater
Sludge
Existing Facilities
Proposed Improvements
New Facilities
(MGD) Flow Volume C0 ADF

:1
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a
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•
Jar--• DISCP.ARGE £,QJNT ' • :-
ti; �- , -'-- VALDESE WASTEWATER TREATMENT PLANT
•
.
. .--. - CATAWBA RIVER (LAKE RllOD1ESS) l •.r
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�• e�Cln �. .•
Location Map
Town of Valdese WWTP Discharge Point
Source: USGS - Drexel Quad, NC
jft/r.r
h
Scale 1:24 000
Page 14 of 25

NC DENR / DWQ / NPDES PERMIT APPLICATION - STANDARD FORM A
Municipal Facilities with permitted flows > 1 MGD or with pretreatment programs
SECTION I1. BASIC DISCHARGE DESCRIPTION
Complete this section for each present or proposed discharge indicated in Section 1.
All values for an existing discharge should be representative of the twelve previous months of operation.
(If this is a proposed discharge, values should reflect best engineering estimates.)
1 . Facility Discharges, Number and Discharge Volume (see instructions)
Specify the number of discharges in this application and the volume of water discharged or lost to each of the categories below.
Estimate average volume per day in MGD. Do not include intermittent discharges, overflows, bypasses or seasonal discharges from
lagoons, etc.
Discharge To:
Number of Discharge Points
Total Volume Discharged (MGD)
Surface Water
1
10.5
Other (describe below)
TOTAL
1
10.5
If 'other' is specified, describe:
2. Outfall Number: 001
Assign a three -digit number beginning with 001 for the point of discharge covered by the first description. Discharge
serial numbers should be consecutive for each additional discharge described; hence, the second serial number
should be 002, the third 003, etc.
3. Discharge to End Date
If the discharge is scheduled to be discontinued within the next 5 years, give the date (with best estimate) the
discharge will end:
Give the reason(s) for discontinuing this discharge in your cover letter.
4. Receiving Stream Name
Name the waterway at the point of discharge. Use the name of the waterway by which it is usually designated on
published maps of the area. If possible, refer to one of the map series published by the U.S. Geological Survey. If the
discharge is to an unnamed tributary, please so state; and give the name of the first body of water fed by that
tributary which is named on the map, e.g., Unnamed tributary to McIntire Creek, where McIntire Creek is the first
water way that is named on the map and is reached by the discharge.
Catawba River (Lake Rhodhiss)
5. Outfall Structure
Describe the outfall structure and any significant changes since the last permit was issued (repairs, shoreline
maintenance, etc.).
28" diam. sewer pipe discharges effluent 760 feet into Lake Rhodhiss
Page 15 of 25

r
NC DENR / DWQ / NPDES PERMIT APPLICATION - STANDARD FORM A
Municipal Facilities with permitted flows > 1 MGD or with pretreatment programs
SECTION III. INDUSTRIAL WASTE CONTRIBUTION TO MUNICIPAL
SYSTEM
Submit a separate Section 111 for each Significant Industrial User.
1 . Significant Industrial User (SIU)
An SIU has (or could have) significant impact on the POTW receiving the wastewater or upon the quality of effluent
from the receiving POTW.
Specifically, an SIU:
• has a flow of 50,000 gallons or more per average workday;
• has a flow greater than 5 percent of the total flow carried by the municipal system receiving the waste, or
• has a toxic material in its discharge.
It may be necessary to alter these administrative criteria in certain cases, such as an instance where two or more
contributing industries in combination can produce an undesirable effect on either the municipal facility or the quality
of its effluent.
Name of SIU Alba Waldensian. Inc.
Street address: P.O. Box 100
City: Valdese County Burke
State: North Carolina Zip Code 28690
Telephone Number (828 ) 879-6567
Fax Number (828 ) 879-1745
e-mail address [e-mail]
2. Primary Product or Raw Material
Specify either the principal product or the principal raw material and the maximum quantity per day produced or
consumed. Quantities are to be reported in the units of measurement for each SIC category at the facility. SIC
categories should use the units of measurement normally used by that industry.
Product
Raw Material
Quantity
Units
Ladies Undergarments
4,000
Ibs/day
3. Flow
Indicate the volume of water discharged into the POTW and whether this discharge is intermittent or continuous
0.083 MGD jg Intermittent ❑ Continuous
Page 16 of 25

NC DENR / DWQ / NPDES PERMIT APPLICATION - STANDARD FORM A
Municipal Facilities with permitted flows 1 MGD or with pretreatment programs
SECTION III. INDUSTRIAL WASTE CONTRIBUTION TO MUNICIPAL
SYSTEM
Submit a separate Section 11! for each Significant industrial User.
1 . Significant Industrial User (SIU)
An SIU has (or could have) significant impact on the POTW receiving the wastewater or upon the quality of effluent
from the receiving POTW.
Specifically, an SIU:
• has a flow of 50,000 gallons or more per average workday;
• has a flow greater than 5 percent of the total flow carried by the municipal system receiving the waste, or
• has a toxic material in its discharge.
It may be necessary to alter these administrative criteria in certain cases, such as an instance where two or more
contributing industries in combination can produce an undesirable effect on either the municipal facility or the quality
of its effluent.
Name of SIU Burke Mills. Inc.
Street address: P.O. Box 190
City: Valdese County Burke
State: North Carolina
Telephone Number
Fax Number
e-mail address
Zip Code 28690
(828 ) 874-6341
(828 ) 879-7176
[e-mail]
2. Primary Product or Raw Material
Specify either the principal product or the principal raw material and the maximum quantity per day produced or
consumed. Quantities are to be reported in the units of measurement for each SIC category at the facility. SIC
categories should use the units of measurement normally used by that industry.
Product
Raw Material
Quantity
Units
Yarn
65,000
Ibs/day
3. Flow
Indicate the volume of water discharged into the POTW and whether this discharge is intermittent or continuous
0.361 MGD
1 Intermittent O Continuous
Page 17 of 25

NC DENR / DWQ / NPDES PERMIT APPLICATION - STANDARD FORM A
Municipal Facilities with permitted flows > 1 MGD or with pretreatment programs
SECTION III. INDUSTRIAL WASTE CONTRIBUTION TO MUNICIPAL
SYSTEM
Submit a separate Section lU for each Significant Industrial User.
1 . Significant Industrial User (SIU)
An SIU has (or could have) significant impact on the POTW receiving the wastewater or upon the quality of effluent
from the receiving POTW.
Specifically, an SIU:
' has a flow of 50,000 gallons or more per average workday;
' has a flow greater than 5 percent of the total flow carried by the municipal system receiving the waste, or
• has a toxic material in its discharge.
It may be necessary to alter these administrative criteria in certain cases, such as an instance where two or more
contributing industries in combination can produce an undesirable effect on either the municipal facility or the quality
of its effluent.
Name of SIU Carolina Mills
Street address: 705 Lovelady Road
City: Valdese County Burke
State: North Carolina
Telephone Number
Fax Number
e-mail address
Zip Code 28690
(828 ) 879-1040
(828 ) 879-1549
[e-mail]
2. Primary Product or Raw Material
Specify either the principal product or the principal raw material and the maximum quantity per day produced or
consumed. Quantities are to be reported in the units of measurement for each SIC category at the facility. SIC
categories should use the units of measurement normally used by that industry.
Product
Raw Material
Quantity
Units
Fabrics and Cloth
120,000
lbs/day
3. Flow
Indicate the volume of water discharged into the POTW and whether this discharge is intermittent or continuous
1.117 MGD WI Intermittent ❑ Continuous
Page 18 of 25

NC DENR / DWQ / NPDES PERMIT APPLICATION - STANDARD FORM A
Municipal Facilities with permitted flows al MGD or with pretreatment programs
SECTION III. INDUSTRIAL WASTE CONTRIBUTION TO MUNICIPAL
SYSTEM
Submit a separate Section 111 for each Significant Industrial User.
1 . Significant Industrial User (SIU)
An SIU has (or could have) significant impact on the POTW receiving the wastewater or upon the quality of effluent
from the receiving POTW.
Specifically, an SIU:
• has a flow of 50,000 gallons or more per average workday;
• has a flow greater than 5 percent of the total flow carried by the municipal system receiving the waste, or
• has a toxic material in its discharge.
It may be necessary to alter these administrative criteria in certain cases, such as an instance where two or more
contributing industries in combination can produce an undesirable effect on either the municipal facility or the quality
of its effluent.
Name of SIU Houston Hosiery
Street address: P.O. Box 939
City: Valdese County Burke
State: North Carolina Zip Code 28690
Telephone Number
Fax Number
e-mail address
n/a
(828 ) 874-8680
(828 ) 874-8681
2. Primary Product or Raw Material
Specify either the principal product or the principal raw material and the maximum quantity per day produced or
consumed. Quantities are to be reported in the units of measurement for each SIC category at the facility. SIC
categories should use the units of measurement normally used by that industry.
Product
Raw Material
Quantity
Units
Socks
5,000
lbs/day
3. Flow
Indicate the volume of water discharged into the POTW and whether this discharge is intermittent or continuous
0.029 MGD II Intermittent 0 Continuous
Page 19 of 25

NC DENR / DWQ / NPDES PERMIT APPLICATION - STANDARD FORM A
Municipal Facilities with permitted flows >_ 1 MGD or with pretreatment programs
SECTION III. INDUSTRIAL WASTE CONTRIBUTION TO MUNICIPAL
SYSTEM
Submit a separate Section III for each Significant Industrial User.
1 . Significant Industrial User (SIU)
An SIU has (or could have) significant impact on the POTW receiving the wastewater or upon the quality of effluent
from the receiving POTW.
Specifically, an SIU:
• has a flow of 50,000 gallons or more per average workday;
• has a flow greater than 5 percent of the total flow carried by the municipal system receiving the waste, or
• has a toxic material in its discharge.
It may be necessary to alter these administrative criteria in certain cases, such as an instance where two or more
contributing industries in combination can produce an undesirable effect on either the municipal facility or the quality
of its effluent.
Name of SIU VNC
Street address: P.O. Box 340
City: Valdese
State: North Carolina
Telephone Number
Fax Number
e-mail address
n/a
County Burke
Zip Code 28690
(828 )
(828 )
874-4126
874-4455
2. Primary Product or Raw Material
Specify either the principal product or the principal raw material and the maximum quantity per day produced or
consumed. Quantities are to be reported in the units of measurement for each SIC category at the facility. SIC
categories should use the units of measurement normally used by that industry.
Product
Raw Material
Quantity
Units
Fabric and Cloth
35,000
Ibs/day
3. Flow
Indicate the volume of water discharged into the POTW and whether this discharge is intermittent or continuous
0.589 MGD 12 Intermittent 0 Continuous
Page 20 of 25

NC DENR / DWQ / NPDES PERMIT APPLICATION - STANDARD FORM A
Municipal Facilities with permitted flows > 1 MGD or with pretreatment programs
SECTION III. INDUSTRIAL WASTE CONTRIBUTION TO MUNICIPAL
SYSTEM
Submit a separate Section 111 for each Significant Industrial User.
1 . Significant Industrial User (SIU)
An SIU has (or could have) significant impact on the POTW receiving the wastewater or upon the quality of effluent
from the receiving POTW.
Specifically, an SIU:
• has a flow of 50,000 gallons or more per average workday;
• has a flow greater than 5 percent of the total flow carried by the municipal system receiving the waste, or
• has a toxic material in its discharge.
It may be necessary to alter these administrative criteria in certain cases, such as an instance where two or more
contributing industries in combination can produce an undesirable effect on either the municipal facility or the quality
of its effluent.
Name of SIU Robinson Hosiery
Street address: P.O. Box 730
City: Valdese County Burke
State: North Carolina Zip Code 28690
Telephone Number
Fax Number
e-mail address
(828 )
(828 )
n/a
874-2228
879-1660
2. Primary Product or Raw Material
Specify either the principal product or the principal raw material and the maximum quantity per day produced or
consumed. Quantities are to be reported in the units of measurement for each SIC category at the facility. SIC
categories should use the units of measurement normally used by that industry.
Product
Raw Material
Quantity
Units
Socks
4,000
Ibs/day
3. Flow
Indicate the volume of water discharged into the POTW and whether this discharge is intermittent or continuous
0.024 MGD lS! Intermittent O Continuous
Page 21 of 25

NC DENR / DWQ / NPDES PERMIT APPLICATION - STANDARD FORM A
Municipal Facilities with permitted flows >_ 1 MGD or with pretreatment programs
SECTION III. INDUSTRIAL WASTE CONTRIBUTION TO MUNICIPAL
SYSTEM
Submit a separate Section 11l for each Significant Industrial User.
1 . Significant Industrial User (SIU)
An SIU has (or could have) significant impact on the POTW receiving the wastewater or upon the quality of effluent
from the receiving POTW.
Specifically, an SIU:
• has a flow of 50,000 gallons or more per average workday;
• has a flow greater than 5 percent of the total flow carried by the municipal system receiving the waste, or
• has a toxic material in its discharge.
It may be necessary to alter these administrative criteria in certain cases, such as an instance where two or more
contributing industries in combination can produce an undesirable effect on either the municipal facility or the quality
of its effluent.
Name of SIU Valdese Manufacturing Company
Street address: P.O. Drawer 10
City: Valdese County Burke
State: North Carolina
Telephone Number
Fax Number
Zip Code 28690
(828 ) 874-2151
(828 ) 874-2189
e-mail address [e-mail]
2. Primary Product or Raw Material
Specify either the principal product or the principal raw material and the maximum quantity per day produced or
consumed. Quantities are to be reported in the units of measurement for each SIC category at the facility. SIC
categories should use the units of measurement normally used by that industry.
Product
Raw Material
Quantity
Units
Yam
40,000
lbs/day
3. Flow
Indicate the volume of water discharged into the POTW and whether this discharge is intermittent or continuous
0.770 MGD 21 Intermittent 0 Continuous
Page 22 of 25

NC DENR / DWQ / NPDES PERMIT APPLICATION - STANDARD FORM A
Municipal Facilities with permitted flows k 1 MGD or with pretreatment programs
SECTION III. INDUSTRIAL WASTE CONTRIBUTION TO MUNICIPAL
SYSTEM
Submit a separate Section 111 for each Significant Industrial User.
1 . Significant Industrial User (SIU)
An SIU has (or could have) significant impact on the POTW receiving the wastewater or upon the quality of effluent
from the receiving POTW.
Specifically, an SIU:
' has a flow of 50,000 gallons or more per average workday;
' has a flow greater than 5 percent of the total flow carried by the municipal system receiving the waste, or
• has a toxic material in its discharge.
It may be necessary to alter these administrative criteria in certain cases, such as an instance where two or more
contributing industries in combination can produce an undesirable effect on either the municipal facility or the quality
of its effluent.
Name of SIU Valdese Textiles
Street address: P.O. Box 490
City: Valdese
State: North Carolina
Telephone Number
Fax Number
e-mail address
n/a
County Burke
Zip Code 28690
(828 )
(828 )
874-4216
874-4218
2. Primary Product or Raw Material
Specify either the principal product or the principal raw material and the maximum quantity per day produced or
consumed. Quantities are to be reported in the units of measurement for each SIC category at the facility. SIC
categories should use the units of measurement normally used by that industry.
Product
Raw Material
Quantity
Units
Upholstery Fabric
4,900
lbs/day
3. Flow
Indicate the volume of water discharged into the POTW and whether this discharge is intermittent or continuous
0.130 MGD 1g Intermittent O Continuous
Page 23 of 25

NC DENR / DWQ / NPDES PERMIT APPLICATION - STANDARD FORM A
Municipal Facilities with permitted flows >_ 1 MGD or with pretreatment programs
SECTION III. INDUSTRIAL WASTE CONTRIBUTION TO MUNICIPAL
SYSTEM
Submit a separate Section 111 for each Significant Industrial User.
1 . Significant Industrial User (SIU)
An SIU has (or could have) significant impact on the POTW receiving the wastewater or upon the quality of effluent
from the receiving POTW.
Specifically, an SIU:
' has a flow of 50,000 gallons or more per average workday;
• has a flow greater than 5 percent of the total flow carried by the municipal system receiving the waste, or
• has a toxic material in its discharge.
It may be necessary to alter these administrative criteria in certain cases, such as an instance where two or more
contributing industries in combination can produce an undesirable effect on either the municipal facility or the quality
of its effluent.
Name of SIU Valdese Weavers Lovelady and RC
Street address: P.O. Box 70
City: Valdese County Burke
State: North Carolina
Telephone Number
Fax Number
e-mail address
Zip Code 28690
(828 ) 874-2181
(828 ) 874-8925
[e-mail]
2. Primary Product or Raw Material
Specify either the principal product or the principal raw material and the maximum quantity per day produced or
consumed. Quantities are to be reported in the units of measurement for each SIC category at the facility. SIC
categories should use the units of measurement normally used by that industry.
Product
Raw Material
Quantity
Units
Upholstery Fabric
27,000
lbs/day
3. Flow
Indicate the volume of water discharged into the POTW and whether this discharge is intermittent or continuous
0.656 MGD B1 Intermittent 0 Continuous
Page 24 of 25

NC DENR / DWQ / NPDES PERMIT APPLICATION - STANDARD FORM A
Municipal Facilities with permitted flows 1 MGD or with pretreatment programs
SECTION III. INDUSTRIAL WASTE CONTRIBUTION TO MUNICIPAL
SYSTEM
Submit a separate Section 111 for each Significant Industrial User.
1 . Significant Industrial User (SIU)
An SIU has (or could have) significant impact on the POTW receiving the wastewater or upon the quality of effluent
from the receiving POTW.
Specifically, an SIU:
• has a flow of 50,000 gallons or more per average workday;
' has a flow greater than 5 percent of the total flow carried by the municipal system receiving the waste, or
' has a toxic material in its discharge.
It may be necessary to alter these administrative criteria in certain cases, such as an instance where two or more
contributing industries in combination can produce an undesirable effect on either the municipal facility or the quality
of its effluent.
Name of SIU Waldensian Bakery
Street address: P.O. Box 220
City: Valdese County Burke
State: North Carolina Zip Code 28690
Telephone Number
Fax Number
(828 ) 874-2136
(828 ) 874-4910
e-mail address [e-mail]
2. Primary Product or Raw Material
Specify either the principal product or the principal raw material and the maximum quantity per day produced or
consumed. Quantities are to be reported in the units of measurement for each SIC category at the facility. SIC
categories should use the units of measurement normally used by that industry.
Product
Raw Material
Quantity
Units
Baked Goods
450,000
lbs/day
3. Flow
Indicate the volume of water discharged into the POTW and whether this discharge is intermittent or continuous
0.071 MGD lg Intermittent 0 Continuous
Page 25 of 25

Company
Engineering
Planning
Architecture
120 N. Boylan Avenue
Raleigh, NC
27603
919-828-0531
Fax: [phone]
Since 1936
July 25, 2000
Mr. Dave Goodrich, P.E.
Supervisor - NPDES Unit
NCDENR - Division of Water Quality
1617 Mail Service Center
Raleigh, North Carolina 27699-1617
Re: Request for NPDES Permit Modification
Town of Valdese
Lake Rhodhiss Wastewater Treatment Plant Improvements
TWC No. 2749-C
PC001/4ik
tiA41)
z_(lc>(-
� b/vG‘O
$S(c.0-00
Dear Mr. Goodrich:
On behalf of the Town of Valdese, we are submitting this application package in
request for amendment of NPDES No. NC0041696 issued for the operation of the
Lake Rhodhiss Wastewater Treatment Plant. This modification is being requested to
increase the capacity of the treatment plant from 7.5 MGD to 10.5 MGD. Enclosed
please find the following items:
1.) Five copies of NPDES Permit Application - Standard Form A
2.) Check in the amount of $860.00
If you should have any questions or need additional information, please contact me at
[phone].
Sincerely,
OTEI MPANY
arles W. Davis, P.E.
Enclosures
c: Mr. Jeffrey V. Morse, Town Manager, Town of Valdese

valdese
Subject: valdese
Date: Mon, 29 Nov 1999 16:35:30 -0500
From: Susan Wilson <[e-mail]>
To: Charles Weaver <[e-mail]>
jeff morse (former commission member) with town of valdese is fed ex-ing
their renewal application and boy was he confused about question 5 re.
total industrial flow. i think he put down total ind. flow for month on
one answer then daily flow on the next answer. just put this note with
file and whoever gets it can call them or check with pretreatment re.
industrial %. thanks.
4
1 of 1 11/30/99 6:09 AM

GENERAL CONSTRUCTION
a. Provide headworks bypass structure with manual bar screen.
b. Replace two (2) existing mechanical bar screens with two (2) new
mechanical bar screens.
c. Replace existing screenings conveyor with new dual hopper screenings
compactor.
d. Replace two (2) existing chain and bucket grit collectors with two (2) new
chain and bucket grit collections.
e. Replace two (2) existing 125/200 Hp motors for influent pumps 1 & 2 with
two (2) new 200 Hp motors.
f. Provide new pump control panel for existing influent pumps with new
ultrasonic level controller and two (2) new variable frequency drives for
influent pumps 1 & 2.
g. Provide new rake drive for primary clarifier No. 2 and sandblast and paint
clarifier mechanisms for two (2) primary clarifiers.
h. Provide new anoxic basin splitter box.
i. Provide new anoxic basins.
j. Provide new clarifier splitter box.
k. Provide new 110' diameter secondary clarifier.
I. Sandblast and paint clarifier mechanisms for two (2) existing 110'
diameter secondary clarifiers.
m. Provide new RAS/WAS pump station with pump control building.
n. Provide chlorine contact chamber additions.
o. Provide new dechlorination building with sulfur dioxide feed equipment.
P. Provide new chlorine feed equipment.
q. Replace two (2) existing polymer feed systems with two (2) new polymer
feed systems.
r. Provide new diffused aeration system for thickener No. 2.
s. Remove existing rake mechanisms for two (2) 60' diameter sludge
thickeners.
t. Provide new SCADA system and instrumentation.
u. Site work, erosion control and plant piping.
v. Electrical work for the major work items as listed above, unless
specifically noted otherwise.

CATAWBA
SIVER
I a 1\ •'��-7�_ `�F CLEARING
1040 4: 1
TOGIti
SEE !TOTE
MOTE ♦
PROJECT OETIGI.AN I
TOP RIM EXISTING M N.
ELEVATION 100032
..)
\
` NITRIFICATIONBASIN NO 2
♦
TOWN OF VALDESE,N.C.1
G OBRIEN&GERM WACTGWATFIa GA(`II JTIGC
1051
1040
-- LIMITS QF CLEARINGI AREAS
ARE S TO DE NCTS IIA9(DII�
•--405O - EXISTING CONTOURS
-1000- FINISHED CONTOIAS
GRADING PLAN
G 5

NC DENR / DWQ / NPDES PERMIT APPLICATION - STANDARD FORM A
Municipal Facilities with permitted flows > 1 MGD or with pretreatment programs
ECTION 111. INDUSTRIAL WASTE CONTRIBUTION TO MUNICIPAL SYSTEM
Submit a separate Section 111 for each Significant Industrial User.
Significant Industrial User (SIU)
An SIU has (or could have) significant impact on the POTW receiving the wastewater or upon the quality of effluent from the receiving POTW.
Specifically, an SIU:
• has a flow of 50,000 gallons or more per average workday;
• has a flow greater than 5 percent of the total flow carried by the municipal system m receiving the waste, or
• has a toxic material in its discharge.
It may be necessary to alter these administrative criteria in certain cases, such as an instance where two or more contributing industries in
combination can produce an undesirable effect on either the municipal facility or the quality of its effluent.
Name of SIU Waldensian Bakery
Street address 320 Main Street, East
City Valdese Burke
County
State
Zip Code 28690
NC
Telephone Number
Fax Number
e-mail address
( 828 ) 874-2136
Primary Product or Raw Material
Specify either the principal product or the principal raw material and the maximum quantity per day produced or consumed.
Quantities are to be reported in the units of measurement for each SIC category at the facility. SIC categories should use the units of
measurement normally used by that industry.
Product
Bakery
Flow
Raw Material
Quantity
Units
water
0.1200
MGD
Indicate the volume of water discharged into the POTW and whether this discharge is intermittent or continuous
0.1200 MGD
❑ Intermittent ❑ Continuous
4 of4

•
NC DENR / DWQ / NPDES PERMIT APPLICATION - STANDARD FORM A
Municipal Facilities with permitted flows > 1 MGD or with pretreatment programs
SECTION 111. INDUSTRIAL WASTE CONTRIBUTION TO MUNICIPAL SYSTEM
Submit a separate Section Ill for each Significant Industrial User.
1. Significant Industrial User (SIU)
An SIU has (or could have) significant impact on the POTW receiving the wastewater or upon the quality of effluent from the receiving POTW.
Specifically, an SIU:
• has a flow of 50,000 gallons or more per average workday;
• has a flow greater than 5 percent of the total flow carried by the municipal system m receiving the waste, or
• has a toxic material in its discharge.
It may be necessary to alter these administrative criteria in certain cases, such as an instance where two or more contributing industries in
combination can produce an undesirable effect on either the municipal facility or the quality of its effluent.
Name of SIU Valdese Weavers (Rutherford College)
Street address 1000 Perkins Road, SE
City Valdese Burke
County
State NC Zip Code 28690
Telephone Number
Fax Number
e-mail address
( 828 ) 874-2181
( 828 ) 874-1592
2. Primary Product or Raw Material
Specify either the principal product or the principal raw material and the maximum quantity per day produced or consumed.
Quantities are to be reported in the units of measurement for each SIC category at the facility. SIC categories should use the units of
measurement normally used by that industry.
Product
textile
3. Flow
Raw Material
Quantity
Units
water
0.4500
MGD
Indicate the volume of water discharged into the POTW and whether this discharge is intermittent or continuous
0.4500 MGD ❑ Intermittent
❑ Continuous
4 of 4

SIC DENR / DWQ / NPDES PERMIT APPLICATION - STANDARD FORM A
Municipal Facilities with perwiltcd flows > 1 MGD or with pretreatment programs
SECTION I11. INDUSTRIAL WASTE CONTRIBUTION TO MUNICIPAL SYSTEM
Submit a separate Section 111 for each Significant Industrial User.
1. Significant Industrial User (SIU)
An SIU has (or could have) significant impact on the POTW receiving the wastewater or upon the quality of effluent from the receiving POTW.
Specifically, an SIU:
• has a flow of 50,000 gallons or more per average workday;
• has a flow greater than 5 percent of the total flow carried by the municipal system m receiving the waste, or
• has a toxic material in its discharge.
It may be necessary to alter these administrative criteria in certain cases, such as an instance where two or more contributing industries in
combination can produce an undesirable effect on either the municipal facility or the quality of its effluent.
Name of SIU Valdese Weavers (Lovelady)
Street address
280 Crescent Street, NE
City Valdese Burke
County
State
28690
Zip Code
Telephone Number ( 828) 874-2181
Fax Number ( 828 874-1592
NC
e-mail address
2. Primary Product or Raw Material
Specify either the principal product or the principal raw material and the maximum quantity per day produced or consumed.,
Quantities are to be reported in the units of measurement for each SIC category at the facility. SIC categories should use the units of
measurement normally used by that industry.
Product
textiles
3. Flow
Raw Material
Quantity
Units
water
0.3250
MGD"
Indicate the volume of water discharged into the POTW and whether this discharge is intermittent or continuous
0.3250 MGD
❑ Intermittent ❑ Continuous
4 of 4

NC DENR / DWQ / NPDES PERMIT APPLICATION - STANDARD FORM A
Municipal Facilities with permitted flows > 1 MGD or with pretreatment programs
SECTION 111. INDUSTRIAL WASTE CONTRIBUTION TO MUNICIPAL SYSTEM
Submit a separate Section Ill for each Significant Industrial User.
1. Significant Industrial User (SIU)
An SIU has (or could have) significant impact on the POTW receiving the wastewater or upon the quality of effluent from the receiving POTW.
Specifically, an SIU:
• has a flow of 50,000 gallons or more per average workday: ..••• ••• _ •
• has a flow greater than 5 percent of the total flow carried by the municipal system m receiving the waste, or
• has a toxic material in its discharge.
It may be necessary to alter these administrative criteria in certain cases, such as an instance where two or more contributing industries in
combination can produce an undesirable effect on either the municipal facility or the quality of its effluent.
Name of SIU Valdese Textiles
Street address
1901 Main street, E
City Valdese
State NC Zip Code 28690
Burke
County
Telephone Number
Fax Number
e-mail address
( 828 ) 874-4216
( 828) 874-4218
2. Primary Product or Raw Material
j . • , h
pecify either the principal product or the principal raw material and the maximum quantity per day produced or consumed.
Quantities are to be reported in the units of measurement for each SIC category at the facility. SIC categories should use the units of
measurement normally used by that industry.
Product
textile
water
Raw Material
Quantity
0.3971
Units
MGD-
3. Flow
Indicate the volume of water discharged into the POTW and whether this discharge is intermittent or continuous
0.3971 MGD
❑ Intermittent [] Continuous
4 of 4

NC DENR / DWQ / NPDES PERMIT APPLICATION - STANDARD FORM A
Municipal Facilities with permitted flows > 1 MGD or with pretreatment programs
SECTION I11. INDUSTRIAL WASTE CONTRIBUTION TO MUNICIPAL SYSTEM
Submit a separate Section 11! for each Significant industrial User.
1. Significant Industrial User (SIU)
An SIU has (or could have) significant impact on the POTW receiving the wastewater or upon the quality of effluent from the receiving POTW.
Specifically, an SIU:
• has a flow of 50,000 gallons or more per average workday;
• has a How greater than 5 percent of the total How carried by the municipal system m receiving the waste, or
• has a toxic material in its discharge.
It may be necessary to alter these administrative criteria in certain cases, such as an instance where Iwo or more contributing industries in
combination can produce an undesirable effect on either the municipal facility or the quality of its effluent.
Name of SIU Valdese Manufacturing Co.
Street address
312 Columbo Street SW
City Valdese
State NC
Telephone Number
Fax Number
e-mail address
County Burke
Zip Code 28690
( 828 ) 874-2151
( 828 ) 874-2189
2. Primary Product or Raw Material
Specify either the principal product or the principal raw material and the maximum quantity per day produced or consumed.
Quantities are to be reported in the units of measurement for each SIC category at the facility. SIC categories should use the units of
measurement normally used by that industry.
Product
textile
Raw Material
water
Quantity
1.500
Units
MGD
3. Flow
Indicate the volume of water discharged into the POTW and whether this discharge is intermittent or continuous
1.500 MGD
❑ Intermittent ❑ Continuous
4 of 4

1C DENR / DWQ / NPDES PERMIT APPLICATION - STANDARD FORM A
Municipal Facilities with permitted flows > 1 MGD or with pretreatment programs
SECTION I11. INDUSTRIAL WASTE CONTRIBUTION TO MUNICIPAL SYSTEM
Submit a separate Section III for each Significant Industrial User.
1. Significant Industrial User (SIU)
An SIU has (or could have) significant impact on the POTW receiving the wastewater or upon the quality of effluent from the receiving POTW.
Specifically, an SIU:
• has a flow of 50,000 gallons or more per average workday;
• has a flow greater than 5 percent of the total flow carried by the municipal system m receiving the waste, or
• has a toxic material in its discharge.
It may be necessary to alter these administrative criteria in certain cases, such as an instance where two or more contributing industries in
combination can produce an undesirable effect on either the municipal facility or the quality of its effluent.
Name of SIU Kathy Hosiery
Street address
Columbo Street
City Valdese Burke
County
State NC
Zip Code 28690
Telephone Number
Fax Number
e-mail address
( 828) 879-8121
2. Primary Product or Raw Material
Specify either the principal product or the principal raw material and the maximum quantity per day produced or consumed.
Quantities are to be reported in the units of measurement for each SIC category at the facility. SIC categories should use the units of
measurement normally used by that industry.
Product
textile
3. Flow
Raw Material
Quantity
Units
water
0.0660
MGD
Indicate the volume of water discharged into the POTW and whether this discharge is intermittent or continuous
0.0660
enGD ❑ Intermittent
❑ Continuous
4 of4

SC DENR / DWQ / NPDES PERMIT APPLICATION - STANDARD FORM A
Municipal Facilities with permitted flows > 1 MGD or with pretreatment programs
SECTION III. INDUSTRIAL WASTE CONTRIBUTION TO MUNICIPAL SYSTEM
Submit a separate Section I1! for each Significant Industrial User.
1. Significant industrial User (SIU)
An SIU has (or could have) significant impact on the POTW receiving the wastewater or upon the quality of effluent from the receiving POTW.
Specifically, an SIU:
• has a flow of 50,000 gallons or more per average workday;
• has a flow greater than 5 percent of the total flow carried by the municipal system m receiving the waste, or
• has a toxic material in its discharge.
It may be necessary to alter these administrative criteria in certain cases, such as an instance where two or more contributing industries in
combination can produce an undesirable effect on either the municipal facility or the quality of its effluent.
Name of SiU Island Textiles
Street address
340 Morgan Street, SE
City Valdese County Burke
State
NC
Telephone Number
Fax Number
e-mail address
Zip Code 28690
( 828) 874-4126
2. Primary Product or Raw Material
Specify either the principal product or the principal raw material and the maximum quantity per day produced or consumed.
Quantities are to be reported in the units of measurement for each SIC category at the facility. SiC categories should use the units of
measurement normally used by that industry.
Product
textiles
3. Flow
Raw Material
Quantity
Units
water
1.0295
MGD
Indicate the volume of water discharged into the POTW and whether this discharge is intermittent or continuous
1.0295 MGD ❑ Intermittent
0 Continuous
4ofa

9
NC DENR / DWQ / NPDES PERMIT APPLICATION - STANDARD FORM A
Municipal Facilities with permitted flows > 1 MGD or with pretreatment programs
SECTION 111. INDUSTRIAL WASTE CONTRIBUTION TO MUNICIPAL SYSTEM
Submit a separate Section 111 for each Significant Industrial User.
1. Significant industrial User (SIU)
An SIU has (or could have) significant impact on the POTW receiving the wastewater or upon the quality of effluent from the receiving POTW.
Specifically, an SIU:
• has a flow of 50,000 gallons or more per average workday;
• has a flow greater than 5 percent of the total flow carried by the municipal system m receiving the waste, or
• has a toxic material in its discharge.
It may be necessary to alter these administrative criteria in certain cases, such as an instance where two or more contributing industries in
combination can produce an undesirable effect on either the municipal facility or the quality of its effluent.
Name of SIU Carolina Mills
Street address 705 Lovelady Road, NE
City Valdese Burke
County
State NC 28690
Zip Code
Telephone Number
Fax Number
e-mail address
(828 ) 879-1040
2. Primary Product or Raw Material
,.2.-
Specify either the principal product or the principal raw material and the maximum quantity per day produced or consumed.
Quantities are to be reported in the units of measurement for each SIC category at the facility. SIC categories should use the units of
measurement normally used by that industry.
Product
textiles
Raw Material
water
Quantity
1.400
Units
MGD
3. Flow
Indicate the volume of water discharged into the POTW and whether this discharge is intermittent or continuous
1.400 MGD
❑ Intermittent
❑ Continuous
4o14

N°C DENR / DWQ / NPDES PERMIT APPLICATION - STANDARD FORM A
Municipal Facilities with permitted flows > 1 MGD or with prclrcatinent prograins
0
SECTION 1I1. INDUSTRIAL WASTE CONTRIBUTION TO MUNICIPAL SYSTEM
Submit a separate Section 111 for each Significant Industrial User.
1. Significant Industrial User (SIU)
An SIU has (or could have) significant impact on the POTW receiving the wastewater or upon the quality of effluent from the receiving POTW.
Specifically, an SIU:
• has a flow of 50,000 gallons or more per average workday;
• has a How greater than 5 percent of the total flow carried by the municipal system m receiving the waste, or
• has a toxic material in its discharge.
It may be necessary to alter these administrative criteria in certain cases, such as an instance where two or more contributing industries in
combination can produce an undesirable effect on either the municipal facility or the quality of its effluent.
Name of SIU Burke Mills, Inc.
Street address
City
Valdese
191 Sterling Street, NW
County Burke
State NC Zip Code 28690
Telephone Number ( 828) 874-6341
Fax Number
e-mail address
2. Primary Product or Raw Material
Specify either the principal product or the principal raw material and the maximum quantity per day produced or consumed.
Quantities are to be reported in the units of measurement for each SIC category at the facility. SIC categories should use the units of
measurement normally used by that industry.
Product
Raw Material
Quantity
Units
textile
water
0.6917
MGD"
3. Flow
Indicate the volume of water discharged into the POTW and whether this discharge is intermittent or continuous
0.6917MGD
❑ Intermittent ❑ Continuous
4of4

NC DENR / DWQ / NPDES PERMIT APPLICATION - STANDARD FORM A
Municipal Facilities with permitted !lows > 1 MGD or with pretreatment programs
SECTION III. INDUSTRIAL WASTE CONTRIBUTION TO MUNICIPAL SYSTEM
Submit a separate Section 11! for each Significant Industrial User.
1. Significant Industrial User (SIU)
An SIU has (or could have) significant impact on the POTW receiving the wastewater or upon the quality of effluent from the receiving POTW.
Specifically, an SIU:
• has a flow of 50,000 gallons or more per average workday; ••• . ..
• has a flow greater than 5 percent of the total flow carried by the municipal system m receiving the waste, or
• has a toxic material in its discharge.
It may be necessary to alter these administrative criteria in certain cases, such as an instance where two or more contributing industries in
combination can produce an undesirable effect on either the municipal facility or the quality of its effluent.
Name of SIU Alba Waldensian, Inc.
Street address
201 St. Germain Avenue
City Valdese
State
County Burke
Zip Code 28690
NC
Telephone Number
Fax Number
e-mail address
( 828 ) R7Q-6cnn
( 828 ) 879-6527
2. Primary Product or Raw Material •
Specify either the principal product or the principal raw material and the maximum quantity per day produced or consumed.
Quantities are to be reported in the units of measurement for each SIC category at the facility. SIC categories should use the units of
measurement normally used by that industry.
Product
textile
Raw Material
water
Quantity
0.1325
Units
MGD
3. Flow
Indicate the volume of water discharged into the POTW and whether this discharge is intermittent or continuous
0.1325 MGD
❑ Intermittent
❑ Continuous
4 of4

SLUDGE COMPOSTING PERMIT NO. WQ 0001990
TOWN OF VALDESE
Lake Rhodhiss Wastewater Treatment Plant, NPDES Permit No. NC0041696
Process Description:
Composting at the Lake Rhodhiss Plant uses the aerated static pile method. In this
technique, forced aeration is utilized to accelerate the natural composting process in order
to achieve temperatures in the pasteurization range within the 21 day composting period.
The 21 day composting period is an arbitrarily selected minimum requirement and may be
extended when circumstances require longer composting periods.
Dewatered sludge from the plant centrifuges is trucked to the composting pad and
dumped into a waiting bed of bulking agent. The bulking agent used at our facility is wood
chips and/or veneer. The sludge cake is mixed with the bulking agent by repeatedly turning
the pile with a front end loader. The normal mix ratio is approximately 2:1 bulking agent
to sludge cake. The mix ratio is adjusted by the compost operator to provide a suitable
mix dryness. Efforts are to be made to minimize the formation of sludge balls. Mixing
continues until the mixture is suitably uniform.
A bed is constructed for the compost pile consisting of approximately 12 inches of
bulking agent extending the entire length of the pile. Two aeration pipes (four inch
diameter slotted plastic drainage pipe) is placed under the bed and extends for one
hundred feet with the ends connected. The bed is necessary to help evenly distribute the
flow of air through the pile, and to absorb water drainage from the pile.
The pile is constructed by loading the sludge/bulking agent mixture onto the
prepared bed by the front end loader. Effort is made to avoid compacting the compost by
dropping the mixture to hard on the pad or running the loader tires into the pile. The
height of the piles must also be limited to ten foot in order to prevent compacting of the
bottom layers. Pile construction utilizes the extended pile method. Each new pile is built as
an addition to the sides of an existing pile to produce an unbroken line of continuous piles.
Separate piles will be identified for monitoring and tear down by a temperature log kept by
the compost operator. The extended pile method is chosen to minimize heat loss through
the sides of the piles. Pile construction is completed by covering the built pile with at least
a one foot layer of finished compost to serve as an insulating blanket. Less may be used on
an exposed side that will accept another extended pile addition. Final dimensions will be
somewhat variable but the pile addition will be approximately 100'L / 12'W / 10'H .

Aeration is accomplished by (1/2 HP) blowers operating on timed cycles. Each blower
serves a single pile with two air/drainage pipes. Aeration commences as soon as 1/2 of a
compost pile is built. Initial aeration rates are typically 5 minutes on and 30 minutes off.
Aeration time is increased after pasteurization temperatures have been achieved in order to
increase moisture removal from the piles.
After a minimum of 21 days of active composting, the compost pile can be
transferred to a curing pile for a minimum of 30 days. In the curing pile the compost will
have the opportunity to undergo further stabilization and reduction of pathogens. Height
of curing piles will be limited to 10 feet in order to encourage self -ventilation and to
prevent compacting of the lower portions of the pile. The compost operator will maintain
a daily log of all activities on the compost site.
After completion of the curing period, a portion of the compost will be spread on
the compost pad to air dry to make a dry product. After air drying, a portion of the
compost mixture will be loaded into the Royer-Mogenson shredder/sizer unit. Here the
finer particles of the compost mixture will be discharged to a fine compost pile while the
larger particles are separated and discharged in to a bulking agent recycle pile. The
recycled material will be used in conjunction with fresh bulking agent to build new
compost piles. The finished material will be made available to the general public and any
commercial users who may be interested at no cost. Compost may also be obtained
without screening for certain applications.
Monitoring and Analysis Program
Pile temperatures are monitored at three points on each end of the extended pile
cell. Point No.1H is the toe position on the blower(head) end of the pile. This point is
monitored at 2 feet above the concrete pad and 2.5 feet into the pile (including blanket).
Point No.2H is the compost/blanket interface at approximately 4 feet above the concrete
pad (2 feet into the pile). Point No. 3H is the pile interior at approximately 7 feet above
the pad (3 feet into the pile). Points No.'s 1T, 2T, and 3T are the equivalent points on the
end of the pile opposite the blower (tail). These points should represent the lowest
temperatures in the pile owing to air cooling effects on the head end and limited air supply
on the tail end. Given a reasonably uniform pile construction all other points in the pile
may be assumed to reach a higher temperature than the monitoring points.
Monitoring criterion are based upon the Control of Pathogens and Vector
Attraction in Sewage Sludge under 40 CFR Part 503 regulations. Process to Further
Reduce Pathogens as states in 40 CFR 503.32(a)(7), Appendix B(1) mandate when using
the static aerated pile method of composting, the temperature of the sewage sludge must
be maintained at 55 degrees C or higher for three consecutive days. All points will be
monitored twice daily until the this condition has been met.

Vector Attraction Reduction requirements will be met through 40 CFR
503.33(b)(5) which states "the sewage sludge must be aerobically treated for 14 days or
longer during which time the temperature must be over 40 degrees C and the average
temperature higher than 45 degrees C". Piles not meeting this criteria will be recycled by
mixing with fresh sludge cake and bulking agent.
Final compost product is monitored quarterly by an independent lab for metals of
interest and annually for insecticides and organic's of interest. Nutrient analysis will also
be performed on a quarterly basis. Fecal Coliform analysis (MPN) will be performed twice
per month. Results of all analyses is reported to the Division of Environmental
Management. All testing results and temperature monitoring data will be kept on file and
is accessible to the public.
Lake Rhodhiss Wastewater Treatment Plant Sludge Composting Facilities:
The composting site at the Lake Rhodhiss Wastewater Treatment Plant consists of
two acres of concrete surface(5" non -reinforced) and another 3/4 acre of paved area. The
site is sloped and ditched to provide drainage of all leachate and run-off back to the head
of the treatment plant. The site will presently accommodate up to 11 extended pile "cells"
of 100 feet in length. A metal storage shelter provides 5,000 square feet of dry storage for
chips, curing, or finished compost. The Royer-Mogenson shredder/sizer unit is mounted
under one corner of the metal shelter. A 928-F CAT loader is available for composting
operations. Ten blowers and five spares are available for the aerated static piles. The Lake
Rhodhiss Wastewater Lab is also available and equipped for fecal Coliform (MPN)
analysis. Water hydrants are available on site for wetting down the pad and a street
washing truck is available if necessary.
Distribution and Records:
Distribution records consists of copies of receipts for all compost distributed. The
receipt will list the name of the person receiving the compost, the quantity, and the date of
acquisition. One copy of the receipt is given to the patron while the other copy is filed and
maintained at the plant for a period of seven years unless the Division of Environmental
Management suggests a longer period. Technical questions regarding the use of the
compost may be answered by the treatment plant's staff or by contacting the Burke
County Agriculture Extension Service. Compost may be distributed in screened or un-
screened form. Monitoring and analysis records will also be maintained on file at the plant
for a period of at least seven years.

1
270
feet
Town of Valdese Composting Facilities
-4 1120 feet
r
.paved Area
4 _ 420. feet
t
50 feet
1
Ditch
1
t�•-
`' tlauhole
Concrete Pavement
u---�--r-
:Heist 01%elter
,•✓' ;
f •.
Screening
Equipment
120
feet
Catclil, J.u_t
Concrete
Ditch
Active Composting Arca
• •
Concrete Ditch
22U feet
•
•
216
feet
Compost Aeration Blowers
450 feet
4.
r

• i
•
•
Pile Cross Section
Blankets;
3E.
11
Lengthwise View
Compost Pile • 6'
Sludge Cake/Bulking Agent Mix
I''''IAX XYVV/61 :;',(11 A'1' v,-1-1' t.rk,r,r/
Approx. 80' -
•
...
1
Bed
• 2T
• 1'
Blower
Extended Pile Cross . Section End View
Pile No.1
J J
Pile No. 2 Pile No. 3