NC0004944_Permit Issuance_20100902

NPDES DOCUHENT !;CANNING COVER SHEET
NPDES Permit:
NC0004944
Document Type:
Permit Issuance
Wasteload Allocation
Authorization to Construct (AtC)
Permit Modification
Complete File - Historical
Engineering Alternatives (EAA)
Compliance
Instream Assessment (67b)
Speculative Limits
Environmental Assessment (EA)
Permit
History
Document Date:
September 2, 2010
Thin document ifs printed on reufse paper - igriore any
content on the reizerse (side

ern
NCDENR
North Carolina Department of Environment and Natural Resources
Division of Water Quality
Beverly Eaves Perdue Coleen H. Sullins Dee Freeman
Govemor Director Secretary
September 2, 2010
Mr. Stephen Lamb
Performance Fibers Operations, Inc.
7401 Statesville Blvd.
Salisbury, North Carolina 28147
Subject: Issuance NPDES Permit NC0004944
Performance Fibers — Salisbury Facility
Rowan County
Dear Mr. Lamb:
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 October 17, 2007 (or as subsequently
amended.)
This final permit includes the following changes from the draft permit sent to you on July 7, 2010.
• The OCPSF Subpart I table under Part I, Section A., 2 has been corrected to show Measurement
Frequency as Annually for all parameters and the Daily Maximum concentrations as ug/L not mg/L.
• Part I, Section B has been reformatted and the two paragraphs citing Part III, Standard Conditions,
Section B, Paragraph 5 were revised to Part II, Standard Conditions, Section B, Paragraph 11. All of
the other wording remains the same.
• A copy of a blank Annual Summary Data Monitoring Report for Stormwater as discussed in Part I,
Section B, 1. b) (3) is enclosed for your use.
All the changes made in the draft permit are retained in this permit as follows:
• Decreased process and sanitary flows resulted in reduced BOD5 and TSS limitations. BOD5 and
TSS limitations in this permit are based on the Organic Chemical, Plastics, and Synthetic Fibers
technology effluent guidelines, 40 CFR 414, Subparts C and D.
1617 Mail Service Center, Raleigh, North Carolina 27699-1617
Location: 512 N. Salisbury St. Raleigh, North Carolina 27604
Phone: [phone] FAX: [phone] Customer Service: 1-877-623-6748
Internet www.ncwaterquality.org
An Equal Opportunity 1 Affirmative Action Employer
None Carolina
7%aturaiij

r 1- !
• Iron annd Manganese show no reasonable potential to violate water quality standards.
Monitoring requiremennts for both parameters were removed from the! permit.
• The limitations based on OCPSF• 40 CFR 414, Subpart I requirements were revised to include
updated chronic and human health consumption standards. See Part I, Section A. 2.
• The wording, in Part I, Section A. 3, has been changed and the following paragraph
added: If the Permittee monitors any pollutant more frequently then required by this
permit, the results of such monitoring shall be included in the calculation and reporting of
the data submitted on the Discharge Monitoring Report and all AT Forms submitted.
Please review the Section and possible changes in form codes.
• Stormwater requirements in Part I, Section B. have been changed and should be
thoroughly reviewed.
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. The Division may require modification revocation
and reissuance of the permit. This permit does not affect the legal requirements to obtain other permits which
may be required by the Division of Water Quality or permits required by the Division of Land Resources,
Coastal Area Management Act, or any other Federal or Local governmental permits may be required.
If you have questions concerning this permit, please contact Julie Grzyb by e-mail
([e-mail]) or phone at [phone].
Sincerely,
oleen H. Sullins
Enclosure NPDES Permit NC0004944 (Final Permit)
cc: NPDES Files
Central Files
Mooresville Regional Office / Surface Water Protection
e-copy:
Aquatic Toxicology Unit
EPA Region 4 (Final Permit and fact sheet)
Ecosystems Unit/Attn. Carrie Ruhlman
•
1617 Mail Service Center, Raleigh, North Carolina 27699.1617
Location: 512 N. Salisbury St. Raleigh, North Carolina 27604
Phone: [phone] FAX: [phone] Customer Service:1-877-623.6748
Internet: www.ncwaterquality.org
An Equal Opportunity 1 Affirmative Action Employer
NorthCarolina
Naturally

Permit NC0004944
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 provisions 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,
Performance Fibers Operations, Inc.
is hereby authorized to discharge wastewater and stormwater from a facility located at
Performance Fibers - Salisbury Facility
7401 Statesville Blvd.
Salisbury
Rowan County
to receiving waters designated as North Second Creek in the Yadkin -Pee Dee River Basin in accordance with
effluent limitations, monitoring requirements, and other conditions set forth in Parts I, II, III, and IV hereof.
The permit shall become effective October 1, 2010
This permit and the authorization to discharge shall expire at midnight on March 31, 2014.
Signed this day September 2, 2010
`moo en H. Sullins, Director
Division of Water Quality
By Authority of the Environmental Management Commission

Permit NC0004944
SUPPLEMENT TO PERMIT COVER SHEET
All previous NPDES Permits issued to this facility, whether for operation or discharge are hereby revoked, and
as of this issuance, any previously issued permit bearing this number is no longer effective. Therefore, the
exclusive authority to operate and discharge from this facility arises under the permit conditions,
requirements, terms, and provisions included herein.
Performance Fibers
is hereby authorized to:
1. Continue to operate an existing 2.305 MGD activated sludge wastewater treatment facility
located at Performance Fibers Salisbury facility at 7401 Statesville Blvd., in Rowan County. The
treatment system referenced herein consists of the following:
• Bar screen and grit removal;
• Chlorine contact (sanitary wastes)
• Two covered equalization tanks;
• Three aeration basins (one out -of -service);
• Anaerobic groundwater treatment unit (out -of -service);
• Three secondary clarifiers (one out -of -service);
• Three aerated polishing ponds;
• Chemical additional facilities;
• Aerobic digestion; •
• Sludge dewatering; and
• Instrumented flow measurement.
2. Discharge from said treatment works through outfall 001 at the location specified on the
attached map into North Second Creek, a class C water in the Yadkin -Pee Dee River Basin; and
3. Continue to discharge stormwater associated with industrial activity through five outfalls
(outfalls A, B, C, D, and 5) as shown on the attached map. Modifications to the stormwater
conveyance system are authorized by this permit in accordance with documentation to be
included in the facility's Stormwater Pollution Prevention Plan (construction activities must be
authorized under General Permit No. NCG010000).

Latitude: 35°42'40" USGS Quad Name:
Longitude: 80°36'10" Rowan Mills
N
SCALE
1:24,000
(1„ = 2000')
Performance Fibers Operations, Inc.
NC0004944
Receiving Stream: North Second Creek
Stream Classification: C
River Basin: Yadkin Pee Dee
Sub -Basin #: 03-07-06
8-Digit HUC 03040102
County: Rowan

Permit NC0004944,
Part I. Section A.
1. EFFLUENT LIMITATIONS AND MONITORING REQUIREMENTS
Beginning on the effective date of this permit and lasting through the expiration date, the Permittee is
authorized to discharge from Outfall 001. Such discharges shall be limited and monitored by the
Permittee as specified below:
PARAMETER
EFFLUENT LIMITATIONS
MONITORING REQUIREMENTS
Monthly
Average
Daily
Maximum
Measurement
Frequency
Sample
Type
Sample
Location'
Flow (MGD)
2.305
Continuous
Recording
Effluent
BODs
75 lbs/day
187 lbs/day
3/Week
Composite
Effluent
NH3 as N
23 lbs/day
46 lbs/day
Weekly
Composite
Effluent
Total Suspended Solids
120 lbs/day
369 lbs/day
3/Week
Composite
Effluent
Fecal Coliform (geometric mean)
200/100 ml
400/100 ml
Weekly
Grab
Effluent
Dissolved Oxygen
Daily Average than 5.0
3/Week
Grab
Effluent
Dissolved Oxygen
See Note 1
Grab
U,D
Conductivity
See Note 1
Grab
U,D
Temperature
See Note 1
Grab
U,D
Total Copper
Monthly
Composite
Effluent
pH
Between 6.0 and 9.0 Standard
Units
3/Week
Grab
Effluent
Chronic Toxicity2
Quarterly
Composite
Effluent
40 CFR 414 Subpart I
. See Part I, Section A, Number 2
•
Notes:
1. Sample Locations: U - Upstream at least 100 feet above the outfall; D - Downstream approximately eight miles from
the outfall or at Highway 601. Upstream and downstream samples shall be collected three times per week during the
months of June, July, August, and September and once per week during the remaining months of the year. Instream
sampling requirements are provisionally waived in light of the Permittee's participation in the Yadkin -Pee Dee River
Basin Association (the Association). All instream sampling requirements are immediately reinstated should the
Permittee cease participation in the Association.
2. Chronic Toxicity (Ceriodaphnia) P/F @ 34% February, May, August, November; see condition Part I, Section A,
Number 3 of this permit. Toxicity monitoring shall coincide with metals monitoring.
THERE SHALL BE NO DISCHARGE OF FLOATING SOLIDS OR VISIBLE FOAM IN OTHER THAN TRACE AMOUNTS.
ANALYTICAL DATA WHICH IS LESS THAN THE PRACTICAL QUANTITATION LEVEL SHALL BE REPORTED AS SUCH AND CONSIDERED
ZERO FOR THE PURPOSES OF CALCULATING AVERAGES.

Permit NC0004944
Part I. Section A.
2. EFFLUENT LIMITATIONS AND MONITORING REQUIREMENTS - SUBPART I
Beginning on the effective date of this permit and lasting through the expiration date, the Permittee shall comply with the
limitations and monitoring frequencies established below at outfall 001:
Parameter
Acenaphthene
Acenaphthylene
Acrylonitrile
Anthracene
Benzene
Benzo(a)anthracene
3,4-Benzofluoranthene
Benzo(k)fluoranthene
Benzo(a)pyrene
Bis(2-ethylhexyl) phthalate
Carbon Tetrachloride
Chlorobenzene
Chloroethane
Chloroform
2-Chlorophenol
Chrysene
Di-n-butyl phthalate
1,2-Dichlorobenzene
1,3-Dichlorobenzene
1,4-Dichlorobenzene
1,1-Dichlororthane
1,2-Dichloroethane
1,1-Dichloroethylene
1,2-trans-Dichloroethylene
2,4-Dichlorophenol
1,2-Dichloropropane
1,3-Dichloropropylene
Diethyl phthalate
2,4-Dimethylphenol
Dimethyl phthalate
4,6-Dinitro-o-cresol
2,4-Dinitrophenol
2,4-Dinitrotoluene
2,6-Dinitrotoluene
Ethylbenzene
Fluoranthene
Fluorene
Hexachlorobenzene
Hexachlorobutadiene
Hexachloroethane
. Methyl Chloride
Methylene Chloride
wily
aximum
1bs/dayi. .
0.162
Average` .Maximum
lbs%dayi t = uJ/L :;
0.061
0.162 0.061
0.374 0.102
0.768 0.283
0.105 0.050
0.077 0.041
0.738 0.286
0.127 0.058
0.270 0.085
0.157 0.074
0.449 0.212
0.121 0.085
0.077 0.041
0.162 . 0.061
0.581 0.187
0.069 0.044
0.149 0.058
0.308 0.107
0.633 0.421
0.121 0.080
0.559 0.223
0.099 0.050
0.129 0.052
0.762 0.215
0.339 0.195
0.784 0.311
0.297 0.088
0.162 0.061
0.135 0.055
0.149 0.058
0.523 0.237
0.245 0.110
":Measurement=. Sall p
4� Frequency y Y
Annually Grab
Annually Grab
8.37 Annually Grab
0.15 Annually Grab
Annually Grab
1.04 Annually Grab
1.04 Annually Grab
1.04 Annually Grab
1.04 Annually Grab
Annually Grab
Annually Grab
Annually Grab
Annually Grab
Annually Grab
Annually Grab
1.04 Annually Grab
Annually Grab
Annually Grab
Annually Grab
Annually Grab
Annually Grab
Annually Grab
Annually Grab
Annually Grab
Annually Grab
Annually Grab
Annually Grab
Annually Grab
Annually Grab
Annually Grab
Annually Grab
Annually Grab
Annually Grab
23.76 Annually • Grab
Annually Grab
0.32 Annually Grab
Annually Grab
0.01 Annually Grab
Annually Grab
Annually Grab
Annually Grab
Annually Grab
Effluent
Effluent
Effluent
Effluent
Effluent
Effluent
Effluent
Effluent
Effluent
Effluent
Effluent
Effluent
Effluent
Effluent
Effluent
Effluent
Effluent
Effluent
Effluent
Effluent
Effluent
Effluent
Effluent
Effluent
Effluent
Effluent
Effluent
Effluent
Effluent
Effluent
Effluent
Effluent
Effluent
Effluent
Effluent
Effluent
Effluent
Effluent
Effluent
Effluent
Effluent
Effluent

Permit NC0004944
Part I, Section A.
2. SUBPART I REQUIREMENTS (CONTINUED)
Beginning on the effective date of this permit and lasting through the expiration date, the Permittee shall comply with the
limitations and monitoring frequencies established below at outfall 001:
Parameter
Naphthalene
Nitrobenzene
2-Nitrophenol
4-Nitrophenol
Phenanthrene
Phenol
Pyrene
Tetrachloroethylene
Toluene
1,2,4-Trichlorobenzene
1,1,1-Trichloroethane
1,1,2-Trichloroethane
Trichloroethylene
Vinyl Chloride
Daily
Maximum
lbs/day'
0.162
0.187
0.190
0.341
0.162
0.072
0.184
0.154
0.220
0.385
0.149
0.149
0.149
0.738
Monthly
Average
lbs/day1
0.061
0.074
0.113
0.198
0.061
0.041
0.069
0.061
0.072
0.187
0.058
0.058
0.058
0.286
Daily
Maximum
u g/L
Measurement
Frequency
Annually
Annually
Annually
Annually
Annually
Annually
Annually
Annually
Annually
Annually
Annually
Annually
Annually
Annually
Notes:
1. An OCPSF process flow of 0.33 MGD was used to calculate lbs/day limitations.
Sample
Type
Grab
Grab
Grab
Grab
Grab
Grab
Grab
Grab
Grab
Grab
Grab
Grab
Grab
Grab
Sample.
Location'
Effluent
Effluent
Effluent
Effluent
Effluent
Effluent
Effluent
Effluent
Effluent
Effluent
Effluent
Effluent
Effluent
Effluent

Permit NC0004944
Part I, Section A.
3. CHRONIC TOXICITY PERMIT LIMIT (QUARTERLY) — OUTFALL 001
The effluent discharge shall at no time exhibit observable inhibition of reproduction or significant mortality to
Ceriodaphnia dubia at an effluent concentration of 34 %.
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 February, May, August, and November. 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. If reporting pass/fail results using the parameter code
TGP3B, DWQ Form AT-1 (original) is sent to the below address. If reporting Chronic Value results using the parameter
code THP3B, DWQ Form AT-3 (original) is to be sent to the following address:
Attention: NC DENR / Division of Water Quality
Environmental Sciences Section
1621 Mail Service Center
Raleigh, North Carolina 27699-1621
Completed Aquatic Toxicity Test Forms shall be filed with the Environmental Science§ Section 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 Section 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.
If the Permittee monitors any pollutant more frequently then required by this permit, the results of such monitoring shall
be included in the calculation and reporting of the data submitted on the DMR and all AT Forms submitted.
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.

Pgrmit NC0004944
Part I. Section B.
1. FINAL LIMITATIONS AND CONTROLS FOR STORMWATER DISCHARGES
During the period beginning on the effective date of the permit and lasting until expiration, the permittee is authorized to
discharge stormwater from outfalls A, B, C, D, and 5. Such discharges shall be controlled, limited and monitored as
specified below.
a) STORMWATER POLLUTION PREVENTION PLAN
The permittee shall develop and continue to update a Stormwater Pollution Prevention Plan, herein after referred to as
the Plan. The Plan shall be considered public information and shall include, at a minimum, the following items:
(1) Site Plan. The site plan shall provide a description of the physical facility and the potential pollutant sources
which may be expected to contribute to contamination of stormwater discharges. The site plan shall contain
the following:
(a) A general location map (USGS quadrangle map or appropriately drafted equivalent map), showing the
facility's location in relation to transportation routes and surface waters, the name of the receiving
water(s) to which the stormwater outfall(s) discharges, or if the discharge is to a municipal separate
storm sewer system, the name of the municipality and the ultimate receiving waters, and accurate
latitude and longitude of the point(s) of discharge. The general location map (or alternatively the site
map) shall identify whether each receiving water is impaired (on the state's 303(d) list of impaired
waters) or is located in a watershed for which a TMDL has been established, and what the
parameter(s) of concern are.
(b) _ A narrative description of storage practices, loading and unloading activities, outdoor process areas, dust
or particulate generating or control processes, and waste disposal practices. A narrative description of the
potential pollutants which could be expected to be present in the stormwater discharge from each outfall.
(c) A site map drawn to scale (including a distance legend) showing: the site property boundary, the
stormwater discharge outfalls, all on -site and adjacent surface waters and wetlands, industrial activity
areas (including storage of materials, disposal areas, process areas, loading and unloading areas, and haul
roads), site topography, all drainage features and structures, drainage areas for each outfall, dincction of
flow in each drainage area, industrial activities occurring in each drainage area, buildings, existing BMPs,
and impervious surfaces. The site map must indicate the percentage of each drainage area that is
impervious.
(d) A list of significant spills or leaks of pollutants that have occurred at the facility during the three (3)
previous years and any corrective actions taken to mitigate spill impacts.
(e) Certification that the stormwater outfalls have been evaluated for the presence of non-stormwater
discharges. The certification statement will be signed in accordance with the requirements found in Part
11, Standard Conditions, Section B, Paragraph 11. The permittee shall re -certify annually that the
stormwater outfalls have been evaluated for the presence of non-stormwater discharges.
(2) Stormwater Management Plan. The stormwater management plan shall contain a narrative description of
the materials management practices employed which control or minimize the exposure of significant
materials to stormwater, including structural and nonstructural measures. The stormwater management
plan, at a minimum, shall incorporate the following:
(a) Feasibility Study. A review of the technical and economic feasibility of changing the methods of
operations and/or storage practices to eliminate or reduce exposure of materials and processes to
stormwater. Wherever practical, the permittee shall prevent exposure of all storage areas, material
handling operations, and manufacturing or fueling operations. In areas where elimination of exposure is
not practical, the stormwater management plan shall document the feasibility of diverting the stormwater
runoff away from areas of potential contamination.

Permit.NC0004944
(b) Secondary Containment Requirements and Records. 'Secondary containment is required for: bulk storage
Of liquid materials; storage in any amount of Section 313 of Title III of the Superfund Amendments and
Reauthorization Act (SARA) water priority chemicals; and storage in any amount of hazardous
substances, in order to prevent leaks and spills from contaminating stormwater runoff. A table or
summary of all such tanks and stored materials and their associated secondary containment areas shall
be maintained. If the secondary containment devices are connected to stormwater conveyance systems,
the connection shall be controlled by manually activated valves or other similar devices (which shall be
secured closed with a locking mechanism), and any stormwater that accumulates in the containment area
shall be at a minimum visually observed for color, foam, outfall staining, visible sheens and dry weather
flow, prior to release of the accumulated stormwater. Accumulated stormwater shall be released if found
to be uncontaminated by any material. Records documenting the individual making the observation, the
description of the accumulated stormwater, and the date and time of the release shall be kept for a period
of five years.
(c) BMP Summary. A listing of site structural and non-structural Best Management Practices (BM P) shall be
provided. The installation and implementation of BMPs shall be based on the assessment of the potential
for sources to contribute significant quantities of pollutants to stormwater discharges and data collected
through monitoring of stormwater discharges. The BMP Summary shall include a written record of the
specific rationale for installation and implementation of the selected site BMPs. The BMP Summary shall
be reviewed and updated annually.
(3)
Spill Prevention and Response Plan. The Spill Prevention and Response Plan (SPRP) shall incorporate an
assessment of potential pollutant sources based on a materials inventory of the facility. Facility personnel (or
the team) responsible for implementing the SPRP shall be identified in a written list incorporated into the
SPRP and signed and dated by each individual acknowledging their responsibilities for the plan. A
responsible person shall be on -site at all times during facility operations that have the potential to
contaminate stormwater runoff through spills or exposure of materials associated with the facility
operations. The SPRP must be site stormwater specific. Therefore, an oil Spill Prevention Control and
Countermeasure plan (SPCC) may be a component of the SPRP, but may not be sufficient to completely
address the stormwater aspects of the SPRP. The common elements of the SPCC with the SPRP may be
incorporated by reference into the SPRP.
(4) Preventative Maintenance and Good Housekeeping Program. A preventative maintenance and good
housekeeping program shall be:developeil. The program:shall list all stormwater control systems, •
stormwater discharge outfalls, all on -site and adjacent surface waters and wetlands, industrial activity areas
(including material storage areas, material handling areas, disposal areas, process areas, loading and
unloading areas, and haul roads), all drainage features and structures, and existing structural BM Ps. The
program shall establish schedules of inspections, maintenance, and housekeeping activities of stormwater
control systems, as well as facility equipment, facility areas, and facility systems that present a potential for
stormwater exposure or stormwater pollution. Inspection of material handling areas and regular cleaning
schedules of these areas shall be incorporated into the program. Timely compliance with the established
schedules for inspections, maintenance, and housekeeping shall be recorded in writing and maintained in the
SPPP:
(5)
Employee Training. Training programs shall be developed and training provided at a minimum on an annual
basis for facility personnel with responsibilities for: spill response and cleanup, preventative maintenance
activities, and for any of the facility's operations that have tlie•potential to contaminate stormwater runoff.
Facility personnel (or team) responsible for implementing the training shall be identified, and their annual
training shall be documented by the signature of each employee trained.
(6) Responsible Party. The Stormwater Pollution Prevention Plan shall identify a specific position(s)
responsible for the overall coordination, development, implementation, and revision to the Plan.
Responsibilities for all components of the Plan shall be documented and position assignments provided.
(7)
Plan Amendment. The permittee shall amend the Plan whenever there is a change in design, construction,
operation, or maintenance_which has a significant effect on the potential for the discharge of pollutants to
surface waters. All aspects of the Stormwater Pollution Prevention Plan shall be reviewed and

Permit NC0004944
(8)
(9)
•
updated on an annual basis. The annual update shall include an updated list of significant spills or leaks of
pollutants for the previous three years, or the notation that no spills have occurred. The annual update shall
include written re -certification that the stormwater outfalis have been evaluated for the presence of non-
stormwater discharges. Each annual update shall include a documented re-evaluation of the effectiveness of
the BMPs listed in the BMP Summary of the Stormwater Management Plan.
The Director may notify the permittee when the Plan does not meet one or more of the minimum
requirements of the permit. Within 30 days of such notice, the permittee shall submit a time schedule to the
Director for modifying the Plan to meet minimum requirements. The permittee shall provide certification in
writing (in accordance with Part II,.Standard Conditions, Section B, Paragraph 11 to the Director that the
changes have been made.
Facility Inspections. Inspections of the facility and all stormwater systems shall occur as part of the
Preventative Maintenance and Good Housekeeping Program at a minimum on a semi-annual schedule, once
during the first half of the year (January to June), and once during the second half (July to December), with at
least 60 days separating inspection dates (unless performed more frequently than semi-annually). These
facility inspections are different from, and in addition to, the stormwater discharge characteristic monitoring
required in Section B. 1. b) below.
Implementation. The permittee shall implement the Plan. Implementation of the Plan shall include
documentation of all monitoring, measurements, inspections, maintenance activities, and training provided
to employees, including the log of the sampling data and of actions taken to implement BMPs associated with
the industrial activities, including vehicle maintenance activities. Such documentation shall be kept on -site
for a period of five years and made available to the Director or the Director's authorized representative
immediately upon request.
b) MINIMUM MONITORING AND REPORTING REQUIREMENTS
(1) Analytical monitoring of stormwater discharges shall be performed as specified in Table 1. All samples
shall be collected from a discharge resulting from a representative storm event. The required monitoring will
result in a minimum of ten analytical samplings being conducted over the term of the permit at each
stormwater discharge outfall (SDO).
A representative storm event is a storm event that measures greater than 0.1 inches of rainfall. The time
between this storm event and the previous storm event measuring greater than 0.1 inches must be at least 72
hours. A single storm event may have a period of no precipitation of up to 10 hours. For example, if it rains
but stops before producing any collectable discharge, a sample may be collected if the next rain producing a
discharge begins within 10 hours.
(2) If the stormwater is controlled by a detention pond, and that pond discharges only in response to a storm
event exceeding a 25-year, 24-hour storm, the pond shall be considered a non -discharging stormwater control
system and not subject to NPDES requirements, unless the discharge causes a violation of water quality
standards.
(3) Stormwater samples analyzed in accordance with the terms of this permit shall be submitted on forms
provided by the Director no later than March 1 following the year in which sampling was required to the
DWQ Central Office. Stormwater samples analyzed in accordance with the terms of this permit shall be
submitted to the Division on Discharge Monitoring Report forms provided by the Director. The permittee
shall also submit an Annual Summary Data Monitoring Report to the appropriate DWQ Regional Office
(RO) by March 1 of each year. The submittal shall be on forms supplied by the Division. Addresses for each
RO can be found here: http://portal.ncdenr.org/web/wq/home/ro/
(4) Specific monitoring requirements:
(a) Stormwater from Performance Fibers - Salisbury. Monitoring in Table 1 applies to all of the stormwater
discharges associated with industrial activity that discharge to the surface waters of the state.

. Permit NC0004944
Table 1. Analytical Stormwater Monitoring Requirements
Discharge
Characteristics
Units
Measurement
Frequencyl
Sample
Type2
Sample
Location3
Total Suspended Solids
mg/L
semi-annual
Grab
SDO
Biochemical Oxygen Demand (BOD), 5-
day, 20 °C
mg/L
semi-annual
Grab
SDO
Total Petroleum Hydrocarbons (TPH),
EPA Method 1664A (SGT-HEM)
mg/L
semi-annual
Grab
SDO
Total Nitrogen (TN)4
mg/L
semi-annual
Grab
SDO
Total Phosphorus (TP)4
mg/L
semi-annual
Grab
SDO
pH
standard
semi-annual
Grab
SDO
Total Rainfalls
inches
semi-annual
Rain Gauge
-
Footnotes:
1
2
3
Measurement Frequency: Twice per year during a representative storm event.
Grab samples shall be collected within the first 30 minutes of discharge.
Sample Location: Samples shall be collected at each stormwater discharge outfall .(SDO) unless representative
outfall status has been granted.
4 The permittee may discontinue monitoring for TN and TP after four (4) consecutive samples if all values are
below the benchmarks in Table 4.
5 For each sampled representative storm event the total precipitation must be recorded. An on -site rain gauge or
local rain gauge reading must be recorded.
The permittee shall complete the minimum 11 analytical samplings in accordance with the schedule specified
below in Table 2. A minimum of 60 days must separate Period 1 and Period 2 sample dates unless monthly
monitoring has been instituted under a Tier Two response.
Table 2. Monitoring Schedule
Monitoring period1 `
Sample Number
Start•
;';End
Year 1- Period 1
1
April 1, 2010
June 30, 2010
Year 1- Period 2
' 2
July 1, 2010
December 31, 2010
Year 2 - Period 1
3
January 1, 2011
June 30, 2011
Year 2 - Period 2
4
July 1, 2011
December 31, 2011
Year 3 - Period 1
5
January 1, 2012
June 30, 2012
Year 3 - Period 2
6
July 1, 2012
December 31, 2012
Year 4 - Period 1
7
January 1, 2013
June 30, 2013
Year 4 - Period 2
8
July 1, 2013
December 31, 2013
Year 5 - Period 1
• 9
January 1, 2014
June 30, 2014
Year 5 - Period 2
10
July 1, 2014
December 31, 2014
During Renewal Process2
11+
January 1, 2015
March 30, 2015
Footnotes:
1 If no discharge occurs during the sampling period, the permittee must record "No Flow" on a monitoring report
within 30 days of the end of the sampling period and maintain this record in the SPPP.
2 Maintain semi-annual monitoring during permit renewal process. If at the expiration of this permit, the
permittee has submitted an application for renewal of coverage before the submittal deadline, the permittee will
be considered for renewed coverage. The applicant must continue semi-annual monitoring until the renewed
permit is issued.
(b) Facilities which have any vehicle maintenance activity occurring on -site which uses more than 55
gallons anew motor oil per month when averaged over the calendar year shall perform analytical
monitoring as specified below in Table 3. This monitoring shall be performed at all stormwater discharge

Permit NC0004944
outfalls which discharge stormwater runoff from vehicle maintenance areas, in accordance with the
schedule presented in•Table 2. All analytical monitoring shall be performed during a representative
storm event.
Table 3. Analytical Monitoring Requirements for On -Site Vehicle Maintenance
Discharge Characteristics
Units
Measurement
Frequency1
Sample
Type2 1
Sample
Location3
pH
standard
semi-annual
Grab
SDO
Total Petroleum Hydrocarbons (TPH),
EPA Method 1664A (SGT-HEM)
mg/1
semi-annual
Grab
SDO
Total Suspended Solids (TSS)
mg/I
semi-annual
Grab
. SDO
Total Rainfall4
inches
semi-annual
Rain gauge
-
New Motor Oil Usage
gallons/month
semi-annual
Estimate
-
Footnotes:
1
Measurement Frequency: Twice per year during a representative storm event, for each year until either another
permit is issued for this facility or until this permit is revoked or rescinded. If at the end of this permitting cycle
the permittee has submitted the appropriate paperwork for a renewal permit before the submittal deadline, the
permittee will be considered for a renewal application. The applicant must continue semi-annual monitoring
until the renewed permit is issued. See Table 2 for schedule of monitoring periods through the end of this
permitting cycle.
2 If the stormwater runoff is controlled by a stormwater detention pond a grab sample of the discharge from the
pond shall be collected within the first 30 minutes of discharge from the pond.
3 Sample Location: Samples shall be collected at each stormwater discharge outfall (SDO) that discharges
stormwater runoff from area(s) where vehicle maintenance activities occur.
4 For each sampled representative storm event the total precipitation must be recorded. An on -site or local rain
gauge reading must be recorded.
Monitoring results shall be compared to the benchmark values in Table 4. The benchmark values in Table 4 are
not permit limits but should be used as guidelines for the permittee's SPPP. Exceedances of benchmark values
require the permittee to increase monitoring, increase management actions, increase record keeping, and/or install
stormwater Best Management Practices (BMPs), as provided in 3. below.
(5) The permittee shall report the analytical results from each sample within the monitoring period. The
permittee shall compare monitoring results to the benchmark values in Table 4. The benchmark values in
Table 4 are not permit limits but should be used as guidelines for the permittee's Stormwater Pollution
Prevention Plan (SPPP). Exceedances of benchmark values require the permittee to increase monitoring,
increase management actions, increase record keeping, and/or install stormwater Best Management Practices
(BMPs) in a tiered program. See the descriptions of Tier One and Tier Two.
• Table 4. Benchmark Values for Analytical Monitoring •
Discharge Characteristics
Units
Benchmark
Total Suspended Solids (TSS)
mg/L
100
Biochemical Oxygen Demand (BOD)
mg/L
30
Total Petroleum Hydrocarbons (TPH),
EPA Method 1664A (SGT-HEM)
mg/L
15
Total Nitrogen
mg/L
30
Total Phosphorus
mg/L
2
pH -
standard
- 6 - 9

Permit NC0004944
Tier One
If: The first valid sampling results are above a benchmark value, or outside of the benchmark range, for any
parameter at any outfall;
Then: The permittee shall:
1. Conduct a stormwater management inspection of the facility within two weeks of receiving sampling
results.
2. Identify and evaluate possible causes of the benchmark value exceedance.
3. Identify potential and select the specific: source controls, operational controls, or physical improvements
to reduce concentrations of the parameters of concern, or to bring concentrations within the benchmark
range.
4. Implement the selected actions within two months of the inspection.
5. Record each instance of a Tier One response in the Stormwater Pollution Prevention Plan. Include the
date and value of the benchmark exceedance, the inspection date, the personnel conducting the
inspection, the selected actions, and the date the selected actions were implemented.
Tier Two
If: During the term of this permit, the first valid sampling results from two consecutive monitoring periods are
above the benchmark values, or outside of the benchmark range, for any specific parameter at a specific
discharge outfall;
Then: The permittee shall:
1. Repeat all the required actions outlined above in Tier One.
2. Immediately institute monthly monitoring for all parameters at every outfall where a sampling result
exceeded the benchmark value for two consecutive samples. Monthly (analytical and qualitative)
monitoring shall continue until three consecutive sample results are below the benchmark values or
within the benchmark range.
3. If no discharge occurs during the sampling period, the permittee is required to record "No Flow" on a
monthly monitoring report to comply with reporting requirements.
4. Maintain a record of the Tier Two response in the Stormwater Pollution Prevention Plan.
During the term of this permit, if the valid sampling results required for the permit monitoring periods exceed the
benchmark value, or are outside the benchmark range, for any specific parameter at any specific outfall on four
occasions, the permittee shall notify the DWQ Regional Office Supervisor in writing within 30 days of receipt of
the fourth analytical results. DWQ may but is not limited to:
• require that the permittee revise, increase, or decrease the monitoring frequency for the remainder of the
permit;
• require the permittee to install structural stormwater controls;
• require the permittee to implement other stormwater control measures; or
• require that the permittee implement site modifications to qualify for the No Exposure Exclusion.
(6) If a facility is required to sample multiple stormwater discharge locations, the permittee may petition the
Director to sample at a reduced number of outfalls. These outfalls would be granted "Representative Outfall
Status" (ROS). DWQ may grant Representative Outfall Status if discharges from a single outfall are
representative of discharges from multiple outfalls. Approved ROS will reduce the number of outfalls where
analytical sampling requirements apply. Qualitative observations shall fie recorded for all outfall locations.
(7) This site discharges to impaired waters experiencing problems with biological integrity (North Second Creek)
and excessive nutrient loading (High Rock Lake watershed). If a Total Maximum Daily Load (TMDL) is
approved for this segment of North Second Creek or High Rock Lake, the permittee may be required to
monitor for the pollutant(s) of concern in the future and submit results to the Division of Water Quality. The
Division will consider the monitoring results in determining whether additional BMPs are needed to control
the pollutant(s) of concern to the maximum extent practicable.

Permit NC0004944
If additional BM Ps are needed to achieve the required level of control, the permittee will be required to (1)
develop a strategy for implementing appropriate BMPs, and (2) submit a timetable for incorporation of those
BMPs into the permitted Stormwater Pollution Prevention Plan.
(8) Qualitative monitoring requires a visual inspection of each stormwater outfall regardless of representative
outfall status and shall be performed as specified in Table 5, during the analytical monitoring event. [If
analytical monitoring is not required, the permittee still must conduct semi-annual qualitative monitoring.]
Qualitative monitoring is for the purpose of evaluating the effectiveness of the Stormwater Pollution
Prevention Plan (SPPP) and assessing new sources of stormwater pollution.
Table 5. Qualitative Stormwater Monitoring Requirements
Discharge Characteristics
Frequencyl
semi-annual
:Monitoring Location2
SDO
Color
Odor
semi-annual
SDO
Clarity
semi-annual
SDO
Floating Solids
semi-annual
SDO
Suspended Solids
semi-annual
SDO
Foam
semi-annual
SDO
Oil Sheen
semi-annual
SDO
Erosion or deposition at the outfall
semi-annual
SDO
Other obvious indicators of stormwater
pollution
semi-annual
SDO
Footnotes:
1
Measurement Frequency: Twice per year during a representative storm event, for each year until either
another permit is issued for this facility or until this permit is revoked or rescinded. If at the end of this
permitting cycle the permittee has submitted the appropriate paperwork for a renewal permit before the
submittal deadline, the permittee will be considered for a renewal application. The applicant must continue
semi-annual monitoring until the renewed permit is issued. See Table 2 for schedule of monitoring periods
through the end of this permitting cycle.
2 Monitoring Location: Qualitative monitoring shall be performed at each stormwater discharge outfall (SDO)
regardless of representative outfall status. •
In the event an atypical condition is noted at a stormwater discharge outfall, the permittee shall document the
suspected cause of the condition and any actions taken in response to the discovery. This documentation will be
maintained with the SPPP.
(9) The permittee shall record the required qualitative monitoring observations on the SDO Qualitative Monitoring
Report form provided by the Division, and shall retain the completed forms on site. Visual monitoring results
should not be submitted to the Division, except upon DWQ's specific requirement to do so.
c) RECORDS RETENTION
Along with the Stormwater Pollution Prevention Plan, qualitative monitoring shall be documented and records
maintained at the facility. Copies of analytical monitoring results shall also be maintained on -site. The permittee
shall retain records of all monitoring information, including all calibration and maintenance records and all
original strip chart recordings for continuous monitoring instrumentation, and copies of all reports required by
this individual permit for a period of at least 5 years from the date of the sample, measurement, report or
application. This period may be extended by request of the Director at any time.
d) BYPASSING OF STORMWATER CONTROL FACILITIES
Bypass is prohibited, and the Director may take enforcement action against a permittee for bypass unless:
(1) The bypass was unavoidable to prevent loss of life, personal, injury or severe property damage; and

Permit NC0004944
(2) There were no feasible alternatives to the bypass, such as the use of auxiliary control facilities, retention of
stormwater or maintenance during normal periods of equipment downtime or dry weather. This condition is
not satisfied if adequate backup controls should have been installed in the exercise of reasonable engineering
judgment to prevent a bypass which occurred during normal periods of equipment downtime or preventive
maintenance; and
(3) The permittee submitted notices as required under, Part III, Section C of this permit.
If the Director determines that it will meet the three conditions listed above, the Director may approve an
anticipated bypass after considering its adverse effects.
e) Stormwater Definitions
(1) Best Management Practices (BMPs)
Measures or practices used to reduce the amount of pollution entering surface waters. BMPs may take the
form of a process, activity, or physical structure. More information on BMPs can be found at:
http://cfpub.epa.gov/npdes/stormwater/menuofbmps/index.cfm.
{2) Bulk Storage of Liquid Products
Liquid raw materials, manufactured products, waste materials or by-products with a single above ground
storage container having a capacity of greater than 660 gallons or with multiple above ground storage
containers having a total storage capacity of greater than 1,320 gallons.
(3)
Municipal Separate Storm Sewere System (MS4)
A stormwater collection system within an incorporated area of local self-government such as a city or town.
(4) No Exposure
A condition of no exposure means that all industrial materials and activities are protected by a storm resistant
shelter or acceptable storage containers to prevent exposure to rain, snow, snowmelt, or runoff. Industrial
materials or activities include, but are not limited to, material handling equipment or activities, industrial
machinery, raw materials, intermediate products, by-products, final products, or waste products. DWQ may
grant a No Exposure Exclusion from NPDES Stormwater Permitting requirements only if a facility complies
with the terms and conditions described in 40 CFR §122.26(g)
(5)
Point Source Discharge
Any discernible, confined and discrete conveyance, including but specifically not limited to, any pipe, ditch,
channel, tunnel, conduit, well, discrete fissure, container, rolling stock, or concentrated animal feeding
operation from which pollutants are or may be discharged to waters of the state.
(6) Representative Outfall Status
When it is established that the discharge of stormwater runoff from a single outfall is representative of the
discharges at multiple outfalls, the DWQ may grant representative outfall status. Representative outfall status
allows the permittee to perform analytical monitoring at a reduced number of outfalls.
(7) Secondary Containment
Spill containment for the contents of the single largest tank within the containment structure plus sufficient
freeboard to allow for the 25-year, 24-hour storm event.
• < (8). Section 313 Water Priority Chemical
A chemical or chemical category which:
(a) Is listed in 40 CFR 372.65 pursuant to Section 313 of Title 111 of the Superfund Amendments and
Reauthorization Act (SARA) of 1986, also titled the Emergency Planning and Community Right -to -Know
Act of 1986;
(b) Is present at or above threshold levels at a facility subject to SARA title I11, Section 313 reporting
requirements; and
(c) That meets at least one of the following criteria:

• • • Permit NC0004•944
(i) Is listed in appendix D of 40 CFR part 122 on either Table II (organic priority pollutants), Table III
(certain metals, cyanides, and phenols) or Table IV (certain toxic pollutants and hazardous.
substances);
(ii) Is listed as a hazardous substance pursuant to section 311(b) (2) (A) of the CWA at 40 CFR 116.4;
or
(iii) Is a pollutant for which EPA has published acute or chronic water quality criteria.
4
(9) Significant Materials
Includes, but is not limited to: raw materials; fuels; materials such as solvents, detergents, and plastic
pellets; finished materials such as metallic products; raw materials used in food processing or production;
hazardous substances designated under section 101(14) of CERCLA; any chemical the facility is required to
report pursuant to section 313 of Title III of SARA; fertilizers; pesticides; and waste products such as ashes,
slag and sludge that have the potential to be released with stormwater discharges.
(10) Significant Spills
Includes, but is not limited to: releases of oil or hazardous substances in excess of reportable quantities
under section 311 of the Clean Water Act (Ref: 40 CFR 110.10 and CFR 117.21) or section 102 of CERCLA
(Ref: 40 CFR 302.4).
(11) Stormwater Associated with Industrial Activity
The discharge from any point source which is used for collecting and conveying stormwater and which is
directly related to manufacturing, processing or raw material storage areas at an industrial site. Facilities
considered to be engaged in "industrial activities" include those activities defined in 40 CFR 122.26(b)(14).
The term does not include discharges from facilities or activities excluded from the NPDES program.
(12) Stormwater Discharge Outfall (SDO)
The point of departure of stormwater from a discernible, confined, or discrete conveyance, including but not
limited to, storm sewer pipes, drainage ditches, channels, spillways, or channelized collection areas, from
which stormwater flows directly or indirectly into waters of the State of North Carolina.
(13) S ormwater Runoff
The flow of water which results from precipitation and which occurs immediately following rainfall or as a
result of snowmelt. .
(14) Total Flow
The flow corresponding to the time period over which the sample collection occurs. The total flow
calculated based on the size of the area draining to the outfall, the amount of the built -upon (impervious)
surfaces within the drainage area, and the total amount of rainfall occurring during the sampling period.
(15) Total Maximum Daily Load (TMDL)
TMDLs are written plans for attaining and maintaining water quality standards, in all seasons, for a specific
water body and pollutant. (A list of approved TMDLs for the state of North Carolina can be found at
http://h2o.enr.state.nc.us/tmdl/)
(16) Vehicle Maintenance Activity
Vehicle rehabilitation, mechanical repairs, painting, fueling, lubrication, vehicle cleaning operations, or
airport deicing operations.
(17) Visible Sedimentation
Solid particulate matter, both mineral and organic, that has been or is being transported by water, air,
gravity, or ice from its site of origin which can be seen with the unaided eye.
(18) 25-year. 24 hour storm event
The maximum 24-hour precipitation event expected to be equaled or exceeded, on the average, once in 25
years.

DENR/DWQ FACT SHEET FOR NPDES PERMIT DEVELOPMENT
NPDES No. NC0004944
Final Fact Sheet (no changes from Draft)
Facility Information
Applicant/Facility Name:
Performance Fibers Operations, Inc. (formerly INVISTA, S.a.r.1.;
KOSA; and Hoechst Celanese)
Applicant Address:
P.O. Box 4, Salisbury, NC 28145-0004
Facility Address:
7401 Statesville Blvd., Salisbury, NC 28147
Permitted Flow
2.305 MGD
Type of Waste:
90% Industrial, 10% Domestic
Facility/Permit Status:
Existing renewal without expansion
County:
Rowan
Stream Characteristics
Receiving Stream
North Second Creek
Summer 7Q10 (cfs)
6.9
303(d) Listed?
No
Winter 7Q10 (cfs):
23
Stream Classification
C
Average Flow (cfs) :
116
Sub -basin
03-07-06
IWC (%) @ 2.305 MGD:
34
Drainage Area (mi2):
116
8-Digit HUC
03040102
Regional Office:
Mooresville
Permit Writer:
Julie Grzyb
USGS Topo Quad:
Salisbury
Date
June 23, 2010
Proposed Changes
• Reduced BOD5 and TSS limitations in accordance with 40 CFR 414, Subparts C and D.
• Removed iron and manganese monitoring.
• Revised OCPSF 40 CFR 414, Subpart I requirements, and include updated chronic and
human health standards.
Background
On March 8, 2008 INVISTA, S. a.r.l. was acquired by an affiliate of Performance Fibers Holdings, Inc. A
permit modification recognizing the name change was issued on April 18, 2008. Prior to INVISTA,
S.a.r.l. the facility was known as KOSA and prior to that it was owned by Hoechst Celanese. Hoechst
Celanese is still the owner of the groundwater remediation site and has an agreement to discharge
treated groundwater into the wastewater treatment system owned and operated by Performance Fibers.
Performance Fibers has applied for a renewal of the NPDES permit for its Salisbury facility. The facility
manufactures polyester resin and polyyester fiber. As such, 40 CFR 414.30 and 414.40 (OCPSF federal
guidelines) are applicable. Primary raw materials include terephthalic acid, ethylene glycol, and fiber
finish oils.
Historically, the site produced polyester staple, filament and chip. Production has steadily declined in
the past 10 years and now the only product manufactured is polyester filament. The filament is used to
reinforce rubber goods such as automotive tires, v-belts, seat belts, etc. This decline in production has
resulted in the shut down of roughly one half of the site. The staple operation has been completely shut
down.
The facility was originally permitted in 1980 at a flow of 1.2 MGD. In 1992 a flow modification request
accompanied the permit renewal application. At that time, Hoechst Celanese requested an increase in
total flow from 1.2 MGD to 2.305 MGD to accommodate the discharge of remediated groundwater
associated with a RCRA site stabilization plan. During the same period, USGS was requested to
evaluate critical low flows and the average flow of the receiving stream. The flows provided by USGS
were half what they had been when the permit was developed at 1.2 MGD. DWQ modeled the
wastewaters in 1993 and established water quality based limits for BOD and ammonia nitrogen.
The most recent renewal application did not request any modification to the NPDES permit nor are any
substantive modifications proposed.
NC0004944 NPDES Fact Sheet
Page 1

Performance Fibers discharges to North Second Creek which is part of the Yadkin -Pee Dee River Basin.
It is not listed on the 303(d) list of impaired waters. As a member of the Yadkin Pee Dee River Basin
Association, Performance Fibers collects in -stream data at two stations. The upstream station,
Q4030000, is located on Second Creek at Highway 81 and Sherrills Ford Road upstream of both
Performance Fibers and the Second Creek WWTP. The downstream station, Q4165000, is located on
Second Creek at US 61 near Salisbury and is downstream of both facilities. Ambient data from 2006
through 2009 show some increase in turbidity downstream. In June of 2008 Performance Fibers
started collecting effluent turbidity samples 4-5 times per month. All samples have shown the effluent
turbidity at less than 20 NTU's.
Wasteload Allocation Summary
According to the NPDES permit application, approximately 0.466 MGD of wastewater is expected to be
generated on any given day. Due to a decrease in production this flow is 44% lower than the wastewater
flow used in the previous permit limit calculations. Current wastewater flow is broken down into the
following components:
Sanitary: 0.049 MGD
WTP Slowdown 0.053 MGD
Boilers & Chillers 0.047 MGD
Finish 0.057 MG
Bandcaster 0.057 MGD
Cooling towers 0.095 MGD
Process 0.057 MGD
Groundwater zero MGD
Process Stormwater 0.051 MGD
0.466 MGD Total
0.317 MGD or 68%
In accordance with EPA guidance, a long-term average process wastewater flow was estimated using
data from August 2006 - August 2009. The long-term average was estimated to be 0.472 MGD. Of that,
approximately 68% is considered process. Finish wastewaters, making up approximately 18% of the
process wastewater, are produced from fiber manufacturing and are regulated by 40 CFR 414, Subpart
C. The remaining 82% of process wastewater comes from bandcaster, contact cooling towers, resin
processing, and process stormwater and are regulated by 40 CFR 414, Subpart D. Currently,
groundwater is not being treated or discharged but the facility wishes to keep this option available. The
attached spreadsheet summarizes the guideline calculations and long-term average flow determination.
Effluent limitations listed in this permiit renewal for TSS and BOD5 are based on OCPSF effluent
guidelines. NH3-N remains water quality limited.
It should be noted that water quality based limits for BOD were determined for the 1993 permit
application based on DWQ's draft wasteload allocation dated May 24, 1993. DWQ's modeling analysis
predicted a minimum DO of 5 mg/L based on a discharge of 1.574 MGD, 131 lb/day BOD5, and 17
lb/day ammonia nitrogen. The modeling used a typical CBOD decay rate and a CBOD/BOD ratio.
These values were adjusted using site specific information, and a minimum BOD limit of 150 lb/day was
established for the summer months with ammonia nitrogen limits of 23 lb/daymonthly average and 46
lb/day daily maximum. BOD limitations determined using the technology based effluent guidelines
were used to set winter BOD limitations. These numbers explain the effluent limitations and monitoring
requirements issued in the last reissuance on January 5, 2006. However, given the current level of
production and the decreased process and sanitary flows, summer and winter BOD limitations for this
permit, were both limited by the technology based effluent guidelines.
NC0004944 NPDES Fact Sheet
Page 2

DMR Data Review
A summary of effluent data for the years, August 2006 through August 2009, is presented in Table 1,
below.
Table 1: Average Monthly DMR Data Summary; Aug. 2006 - Aug. 2009
Flow
(MGD)
BOD
(lb/day)
NH3-N
(lb/day)
TSS
(lb/day)
Fecal
(#/100 mL)
D.O.
(mg/L)
Cu
(ug/L)
Mn
(mg/L)
Fe
(mg/L)
Avg
0.472
25.5
0.90
89
41
8.6
17
0.082
0.41
Max
1.67
85
6.55
320
33
13.7
38
0.17
0.88
Min
0.009
1
<0.1
<2
11
5.3
10
0.015
0.095
Current
Limit
2.305
150; 300 (s)
201;518 (w)
23;46
330;1043
200; 400
> 5.0
Proposed
Limit
2.305
75;187
23;46
120;369
200;400
> 5.0
Monthly average; daily maximum
According to Stephen Lamb at Performance Fibers, the limitation they are concerned about meeting is
the Total Suspended Solids, monthly average limit, of 120 lbs/day. Below are graphs of the facilities TSS
discharge during the past two years (2008-2009). The monthly average TSS graph indicates that the
plant would have been out of compliance about 13% of the time. Mr. Lamb stated that the TSS is a
result of the algae growth in the polishing ponds during the summer months. The facility uses copper
sulfate to control the algae but is concerned about its potential to cause toxicity problems. The new TSS
limit may require additional or improved TSS treatment at the facility.
co
4U
TSS (Monthly avg)
a a a
yeas s
ii
s s
/l a■ e a■
r,
fir,.
\
•
"N. "�
`
4
r
1 3
11 13 15 17 '9 21
Process capability at 3 sigma = 168
400
350
300
250
200
150
100
50
0
TSS (Daily Max)
y
f
r
'•,/
i
I
r
7
I I
1
1
I
I I
I
I I
I
i
1
1
I
f
1
1
1 3
11 13 16 17 19 21 23
Process capability at 3 sigma = 340
NC0004944 NPDES Fact Sheet
Page 3

RPA ANALYSIS
A reasonable potential analysis was conducted for total copper, the only detected toxicant. The analysis
indicated a reasonable potential for copper to exceed the chronic and acute allowable concentrations.
Since these are both Action Level standards and should be reviewed in conjunction with toxicity testing,
it is recommended that monthly monitoring be continued.
Performance Fibers currently samples for Manganese and Iron, monthly. Sampling results from Aug.
2006 through Aug. 2009, shown above in Table 1, indicate Iron has not exceeded the water quality
standard of 1 mg/L. The state does not have a limit for Manganese in freshwater, class C streams, and
sampling results do not indicate significant levels of the pollutant. As a result, effluent monitoring for
Iron and Manganese have been removed from the drafted permit.
TREATMENT
The wastewater treatment facility is a biological process consisting of screening, equalization, aeration
basins, clarification, polishing ponds, aerobic sludge digestion and sludge dewatering. When
groundwater is being recovered it is anaerobically pretreated prior to discharge to the aeration basins
referenced above. The primary contaminant found in the groundwater was ethylene glycol, however 1,4-
dioxane has also been detected. Groundwater pretreatment consists of ultraviolet treatment and
addition of peroxide. As this is an end -of -pipe biological treatment system, the effluent is subject to 40
CFR 414, Subpart I. The second attached spreadsheet calculates OCPSF 40 CFR 414, Subpart I
allocations. For parameters having more stringent water quality limitations than those listed under
OCPSF Subpart I, concentration -based limitations have been installed in the NPDES Permit, Part I,
Section A, Number 2 in accordance with state standards and/or EPA criteria. As there are no clearly
defined metal -bearing or cyanide- bearing wastestreams, limits for total chromium, total copper, total
cyanide, total lead, total nickel and total zinc do not apply.
This permit also authorizes the discharge of stormwater. Stormwater requirements are outlined in Part
I, Section B.
Compliance Summary
A review of DMR data has indicated that compliance with permit conditions is excellent. There are no
noted limitation violations from 2006 through April 2010. Mooresville Regional inspections of the facility
state that the WWTP is in good condition. The inspection also noted that the groundwater remediation
system was shut down and the facility had reached an agreement with EPA for the closure of the
groundwater remediation system. Performance Fibers has passed 18 out of 19 Toxicity tests since Jan.
2006.
Instream Monitoring Requirements
Performance Fibers currently monitors dissolved oxygen, turbidity, pH, temperature, and conductivity
instream. This renewal recommends maintaining instream monitoring. While a review of instream data
does not offer conclusive evidence of a direct impact from this discharge, continued monitoring will
afford all parties the ability to make such a conclusion should water quality degrade in the future.
Proposed Schedule for Permit Issuance
Draft Permit to Public Notice: July 7, 2010 (estimate)
Permit Scheduled to Issue: August 30, 2010 (estimate)
State Contact
If you have any questions regarding any of the above information or the attached permit, please contact
Julie Grzyb at [phone].
NPDES UNIT SIGNOFF: DATE:
NC0004944 NPDES Fact Sheet
Page 4

Performance Fibers - Salisbury Plant
NC0004944
Daily Max
Mon. Avg.
BODS
187
75
TSS
369
120
•
Average Flow from 8/2006 - 8/2009: 0.472 MGD
Based on information provided by the applicant, approximately 68% of the flow discharged on any given day
is considered process wastewater flow for the purposes of guideline calculations. As such, the actual
process wastewater flow average is approximately 0.33 MGD. Of that, roughly 0.06 MGD is covered by
414 Supart C with 0.27 MGD covered by 414 Subpart D.
The process wastewater flow at this facility is split between two 40 CFR 414 subparts, subparts C and D.
Approximately 18 % is subpart C process wastewater with the difference being subpart D process WW.
The subparts are summarized below:
40 CFR 414.31 (Subpart C - All units are mg/L)
Daily Max Mon. Avg.
BOD5
TSS
48
115
18
36
Daily Max
Mon. Avg.
BOD5
64
24
TSS
130
40
Process Flow applicable to subpart C:
Process Flow applicable to subpart D:
0.06 MGD
0.27 MGD
Subpart C Allocation - lbs/day
I Daily Max
BOD5
TSS
24.0192
57.546
Mon. Avg.
9.0072
18.0144
Subpart D Allocation - lbs/day
I Daily Max
BODS
TSS
144.1152
292.734
Mon. Avg.
54.0432
90.072
= -
Daily Max
Mon. Avg.
BODS
18.3897
12.2598 '
TSS
18.3897
12.2598
Total Allocation (Sum of C, D, and Domestic) - lbs/day Existing Allocation
I Daily Max
GODS
TSS
300
1043
Mon. Avg.
150
330
Julie Grzyb
6/24/2010

OCPSF Subpart I Calculations
FACILITY =>
NPDES Permit # =>
OCPSF Flow =>
Op =>
WS Class 9
7Q10s =>
Average Strean Flow = >
Performance Fibers
NC0004944
0.33 MGD
2.305 •
no
6.9 cfs
116 cfs
IWC (%)
34.1 %
3.0"/
Parameter
1
OCPSF
Daily
Maximum
ug/L
2
OCPSF-
Monthly
•Average
R9/L
3
OCPSF'
Daily".,
Maxiniurn
lbs/day
4 5 6 7 8
OCPSF^ Federal .1- xStandard "Human Water`
Monthly Criteria ore ' Aquatic „,.KHealth ; Qapsumpbon
Average . State 31LIfe 7V. ' StandariV Stahaard-
Ibs/day 'Standard "InglL • '=;4pl -
Acenaphthene 59 22 0.162 0.061 FC 60
Acenaphthylene 59 22 0.162 0.061 FC none
Acrylonitrile 242- 96 0.666 0.264 FC none
Anlhracene 59 22 0.162 0.061 FC 0.05
Benzene 136 37 0.374 0.102 SS none
Benzo(a)anthracene 59 22 0.162 0.061 FC none
3.4-Benzofluoranthene 61 23 0.168 0.063 FC none
Benzo(k)fluoranthene 59 22 0.162 0.061 FC none
Benzo(a)pyrene 61 23 0.168 0.063 FC none
Bis(2-ethylhexyl) phthalate 279 103 0.768 0.283 FC none
Carbon Tetrachloride 38 18 0.105 0.050 SS none
Chlorobenzene 28 15 0.077 0.041 FC 140
Chloroethane 268 104 0.738 0.286 FC none
Chloroform 46 21 0.127 0.058 SS none
2-Chlorophenol 98 31 0.270 0.085 FC none
Chrysene 59 22 0.162 0.061 FC none
Di-n-butyl phthalate 57 27 0.157 0.074 FC 9.5
1,2-Dichlorobenzene 163 77 0.449 0.212 FC 470
1,3-Dichlorobenzene 44 31 0.121 0.085 FC 390
1,4-Dichlorobenzene 28 15 0.077 0.041 FC 100
1,1-Dichloroethane 59 22 0.162 0.061 FC 20000
1,2-Dichloroethane 211 68 0.581 0.187 FC none
1,1-Dichloroethylene 25 16 0.069 0.044 FC 5400
1,2-trans-Dichloroethylene 54 21 0.149 0.058 FC none
2,4-Dichlorophenol 112 39 0.308 0.107 FC 74
1,2-Dichloropropane 230 153 0.633 0.421 FC none
1,3-Dichloropropylene 44 29 0.121 0.080 FC 12
Diethyl phthalate 203 81 0.559 0.223 FC ,1200
2,4-Dimethylphenol 36 18 0.099 0.050 FC 320
Dimethyl phthalate 47 19 0.129 0.052 FC 3400
4.6-Dinitro-o-cresol 277 78 0.762 0.215 FC none
2,4-Dinitrophenol 123 71 0.339 0.195 FC 26
2,4-Dinitrotoluene 285 113 0.784 0.311 FC none
2,6-Dinitrotoluene 641 255 1.764 0.702 FC none
Ethytbenzene 108 32 0.297 0.088 FC 97
Fluoranthene 68 25 0.187 0.069 FC 0.11
Fluorene 59 22 0.162 0.061 FC 46
Hexachlorobenzene 28 15 0.077 0.041 FC 76
Hexachlorobutadiene 4§ 20 0.135 0.055 SS 0.95
Hexachloroethane 54 21 0.149 0.058 FC none
Methyl Chloride 190 86 0.523 0.237 FC none
Methylene Chloride 89 40 0.245 0.110 FC none
Naphthalene 59 22 0.162 0.061 FC 330
Nitrobenzene 68 27 0.187 0.074 FC none
2-Nitrophenol 69 41 0.190 0.113 FC 8000
4-Nitrophenol 124 72 0.341 0.198 FC 750
Phenanthrene 59 22 0.162 0.061 FC none
Phenol 26 15 0.072 0.041 FC 530
Pyrene 67 25 0.184 0.069 FC none
Tetrachloroethylene 56 22 0.154 0.061 SS 120
2700 1200
none none
0.25 0.051
40000 8300
51 1.2
0.031 0.0028
0.031 0.0028
0.031 0.0028
0.031 0.0028
2.2 1.2
1.6 0.254
none 130
550 12
170 5.6
400 1
0.031 0.0028
4500 2000
1300 420
960 320
190 63
170000 6700
37 0.38
7100 330
10000 140
none 1
15 0.52
21 0.31
44000 17000
850 380
1100000 270000
280 13
5300 69
3.4 0.11
0.71 0.048
2100 530
140 130
5300 1100
0.00029 0.00028
18 0.44
3.3 1.4
96 2.6
590 4.6
none none
30 17
none none
9700 270
none none
300 300
4000 830
3.3 0.7
6/24/2010
9
10
no 60.00
no none
yes 0.250
no 0.05
yes 51.000
yes 0.031
yes 0.031
yes 0.031
yes 0.031
yes 2.200
yes 1.600
no 140.00
yes 550.00
yes 170.00
no 400.00
yes 0.031
no 10
no 470
no 390.00
no 100.00
no 20,000.00
yes 37.00
no 5,400.00
no 10,000.00
no 74.00
yes 15.00
yes 12
no 1,200
no 320
no 3.400
no 280.00
no 26.00
yes 3.40
yes 0.71
no 97.00
no 0.11
no 46.00
yes 0.000
yes 0.95
yes 3.30
no 96.00
yes 590.00
yes 330.00
no 30.00
no 8,000.00
no 750.00
no none
no 300
no 4,000
yes 3.30
3.38
none
0.16
0.00
32.81
0.02
0.02
0.02
0.02
1.42
1.03
7.89
353.86
109.37
22.54
0.02
0.54
26.48
21.98
5.64
1127.00
23.81
304.29
563.50
4.17
9.65
7.72
67.62
18.03
191.59
15.78
1.47
2.19
0.46
5.47
0.01
2.59
0.000
0.61
2.12
5.41
379.59
212.31
1.69
450.80
42.26
none
16.91
225.40
2.12
0.162
0.162
0.666
0.162
0.374
0.162
0.168
0.162
0.168
0.768
0.105
0.077
0.738
0.127
0.270
0.162
0.157
0.449
0.121
0.077
0.162
0.581
0.069
0.149
0.308
0.633
0.121
0.559
0.099
0.129
0.762
0.339
0.784
1.764
0.297
0.187
0.162
0.077
0.135
0.149
0.523
0.245
0.162
0.187
0.190
0.341
0.162
0.072
0.184
0.154
0.162 OCPSF
0.162 OCPSF
0.161 CHRONIC
0.003 CHRONIC
0.374 OCPSF
0.020 CHRONIC
0.020 CHRONIC
0.020 CHRONIC
0,020 CHRONIC
0.768 OCPSF
0.105 OCPSF
0.077 OCPSF
0.738 OCPSF
0.127 OCPSF
0.270 OCPSF
0.020 CHRONIC
0.157 OCPSF
0.449 OCPSF
0.121 OCPSF
0.077 OCPSF
0.162 OCPSF
0.581 OCPSF
0.069 OCPSF
0.149 OCPSF
0.308 OCPSF
0.633 OCPSF
0.121 OCPSF
0.559 OCPSF
0.099 OCPSF
0.129 OCPSF
0.762 OCPSF
0.339 OCPSF
0.784 OCPSF
0.457 CHRONIC
0.297 OCPSF
0.006 CHRONIC
0.162 OCPSF
0.000 CHRONIC
0.135 OCPSF
0.149 OCPSF
0.523 OCPSF
0.245 OCPSF
0.162 OCPSF
0.187 OCPSF
0.190 OCPSF
0.341 OCPSF
0.162 OCPSF
0.072 OCPSF
0.184 OCPSF
0.154 OCPSF
ver 2.00
MDM & SDP
15 16 17
y,;: ' ti' n + Monttllyy
Daily ,1 ,s� Average
Maximum w '' timit>'?
':_Unit Ibslday.
0.162 lbs/day .0.061
0.162 Ibs/day 0.061
8.367 ug/L
0.147 ug/L
0.374 Ibs/day 0.102
1.038 ug/L
1.038 ug/L
1.038 ug/L
1.038 ug/L
0.768 lbs/day 0.283
0.105 lbs/day 0.050
0.077 lbs/day 0.041
0.738 lbs/day 0.286
0.127 lbs/day 0.058
0.270 Ibs/day 0.085
1.038 ug/L
0.157 lbs/day 0.074
0.449 Ibs/day 0.212
0.121 Ibs/day 0.085
0.077 lbs/day 0.041
0.162 Ibs/day 0.061
0.581 lbs/day 0.187
0.069 lbs/day 0.044
0.149 Ibslday 0.058
0.308 lbs/day 0.107
0.633 lbs/day 0.421
0.121 lbs/day 0.080
0.559 lbs/day 0.223
0.099 Ibs/day 0.050
0.129 lbs/day 0.052
0.762 lbs/day 0.215
0.339 lbs/day 0.195
0.784 lbs/day 0.311
23.762 ug/L
0.297 lbs/day 0.088
0.322 ug/L
0.162 lbs/day • 0.061
0.010 ug/L
0.135 lbs/day 0.055
0.149 Ibs/day 0.058
0.523 lbs/day 0.237
0.245 Ibs/day 0.110
0.162 lbs/day 0.061
0.187 lbs/day 0.074
0.190 lbs/day 0.113
0.341 Ibs/day 0.198
0.162 Ibs/day 0.061
0.072 Ibs/day 0.041
0.184 Ibs/day 0.069
0.154 Ibs/day 0.061

OCPSF Subpart I Calculations
Parameter
OCPSF
Daily
Maximum
pg/L
OCPSF
Monthly
Average
pg/L
OCPSF
Daily
Maximum
Ibs/day
OCPSF
Monthly
Average
lbs/day
Federal
Criteria or
State
Standard
Standard
Aquatic
Life
pg/L
Human
Health
Standard
tig/L
Water
Consumption
Standard
trg/L.'
Carcinogen?
min
criteria
!rg/L
Water Qua!
Allowable
Load
lbs/day
OCPSF
Daily
Maximum
Ibs/day
find min.
Limit
Based On:
Daily
Maximum
Limit
Monthly.
Average
Limit
Ibs.rday
Toluene 80 26 0.220 0.072 SS 11 15000 1300 no 11.00 0.62 0.220 0.220 OCPSF 0.220 Ibslday 0.072
Total Chromium 2770 1110 7.624 3.055 SS 50 none none no 50.00 2.82 7.624 2.818 CHRONIC 146.564 ug/L
Total Copper 3380 1450 9.302 3.991 SS -AL 7 none 1300 no 7.00 0.39 9.302 0.394 CHRONIC 20.519 ug/L
Total Cyanide 1200 420 3.303 1.156 SS 5 140 140 no 5.00 0.28 3.303 0.282 CHRONIC 14.656 ug/L
Total Lead 690 320 1.899 0.881 SS 25 none none no 25.00 1.41 1.899 1.409 CHRONIC 73.282 ug/L 0.881
Total Nickel 3960 1690 10.954 4.651 SS 88 4600 25 no 88.00 4.96 10.954 4.959 CHRONIC 257.953 ug/L 4.651
Total Zinc 2610 1050 7.183 2.890 SS -AL 50 none none no 50.00 2.82 7.183 2.818 CHRONIC 146.564 ug/L
1.2.4-Trichlorobenzene 140 68 0.385 0.187 FC 61 70 35 no 61.00 3.44 0.385 0.385 OCPSF 0.385 Ibs/day 0.187
1,1,1-Trichloroethane 54 21 0.149 0.058 FC none 4.4 0.54 yes 4.40 2.83 0.149 0.149 OCPSF 0.149 Ibslday 0.058
1,1,2-Trichloroethane 54 21 0.149 0.058 FC none 16 0.6 yes 16.00 10.29 0.149 0.149 OCPSF 0.149 Ibs/day 0.058
Trichloroethylene 54 21 0.149 0.058 SS none 30 2.5 yes 30.00 19.30 0.149 0.149 OCPSF 0.149 Ibslday 0.058
Vinyl Chloride 268 104 0.738 0.286 SS none 2.4 0.025 yes 2.40 1.54 0.738 0.738 OCPSF 0.738 Ibslday 0.286
Column Calcs:
1 OCPSF Guidelines (see 40 CFR 414.90)
2 OCPSF Guidelines (see 40 CFR 414.90)
3 col 1 ' OCPSF Flow' 8.3411000
4 col 2 * OCPSF Flow • 8.34/1000
5. 6, 7, 8, 9 from Fed /state water quality standards
10 if WS class then find minimum of col 6, 7, & 8. Otherwise find minimum of col 6 & 7.
11 if parameter is a carcinogen then all load = 8.34 ' Qavg' col 10 /1000. Otherwise all load = 8.34 • 7010 *col 10 /1000.
12 copy of column 3
13 find minimum of col 11 and 12.
14 note which load is lower.
15 if limit is not based on OCPSF guidelines then calculate concentration based on Qp. Otherwise copy OCPSF load
16 If limit is not based on OCPSF guidelines then use units of'ugll'. Otherwise use 'Ids/day.
17 if limit is not based on OCPSF guidelines then leave balnk. Otherwise copy OCPSF limits from col. 4.
6/24/2010

-
Beverly Eaves Perdue
Governor
ern
NCDENR
North Carolina Department of Environment and Natural Resources
Division of Water Quality
Coleen H. Sullins Dee Freeman
Director Secretary
STAFF REVIEW AND EVALUATION
NPDES Permit (Stormwater Permitting Unit Review)
MRO
Facility Name:
NPDES Permit Number:
Facility Location:
Type of Activity:
SIC Code:
Receiving Streams:
Impaired Waterbodies?
River Basin:
Stream Classification:
Proposed Permit Requirements:
Monitoring Data:
Facility Location:
Central Office SPU Staff Contact:
Performance Fibers
NC0004944 (Stormwater included with NPDES WW permit)
Salisbury, NC (Rowan County)
Polyester resin and fiber manufacture
282-1
North Second Creek (index 12-108-21) RE Withrow Creek (index 12-
108-21-3)
Yes: North Second Creek has impaired biological integrity (2006 303d
List). Also drains to High Rock Lake Watershed, which suffers from
nutrient and turbidity impacts.
Yadkin -Pee Dee River Basin, Sub -basin 03-07-06
C
See stormwater portion of draft NPDES permit.
See Table 1
See Figure 1
Bethany Georgoulias, [phone]
Stormwater-related Documents Reviewed:
• NPDES Permit Files and application (rec'd September 2008)
• Yadkin Basinwide Plan (July 2008)
• Final 2006 & DRAFT 2008 303(d) Lists; TMDL Documents
• EPA Sector -Specific Permit (2008)
• Natural Heritage Program's Threatened and Endangered Species Database
• 40 CFR Subchapter N, Stormwater Effluent Guidelines
Stormwater. Factsheet
Page 1 of 6

NC0004944
0
u
V
S
Figure 1: Map of Facility Location
Yadkin - Pee Dee River Basin
South Yadkin River Watershed
8-Digit Huc 03040102
we•s.�• n.uenri
a rsn
• _r1
• WPC&
kae.d
roes. w. •sw
ss•.••
•. rw•a,
s Wor
uaaxsr.• OW/
stDtt sw.•., r•t••• CJ Carty Sum,
4 mu* C> bac
Figure 2: Subwatershed in Yakin River Basin
Page 2 of 6

NC0004944
Central Office Stormwater Permitting Unit Review Summary:
1. Impairment: Withrow Creek is impacted (likely source is agriculture), but not impaired. North Second
Creek is listed as an impaired stream because of impacted biological integrity and turbidity problems.
This site is also located in the High Rock Lake watershed, which is severely affected by excess nutrients
and sediment problems. A TMDL for High Rock Lake is under development.
Draft permit incorporates TMDL language in the analytical monitoring section and maintains
nutrient monitoring.
2. Threatened and Endangered: None identified in NC Natural Heritage Program Virtual Workroom
databases.
3. Stormwater Effluent Guidelines: None from 40 CFR §414 applicable to this activity.
4. EPA MultiSector General Permit: EPA's 2008 MSGP (Sector C, SIC 2821) requires zinc monitoring for this
industry SICs; however, there are no apparent zinc sources in the industrial activities at this site. The
reviewer does not recommend zinc monitoring be added at this renewal.
5. Location: This site discharges stormwater through five (5) stormwater discharge outfalls: SDOs A, B, C, D,
and 5. SDOs A, C, and D discharge to Withrow creek; SDO B and 5 discharge to North Second Creek. SDO
5 collects stormwater from the main manufacturing areas of the site and discharges through a system of
diverter weirs to the WWTP headworks or Number 2 Polishing Pond (this is where dry weather spills
would be routed). Excess water in large storms that overflows the• diverter weirs goes directly to North
'Second Creek.
6. Industrial Changes Since Previous Permit: There is a groundwater remediation program to treat ethylene
glycol contamination (interior system) in the WWTP and 1,4-dioxane (perimeter system) in the polishing
ponds. The program has been shut down for a trial period with EPA approval, and future operation is
unlikely, but the final decision is still pending. Also, production has declined over the past 10 years, and
about half of the site is shutdown. The only product now manufactured is polyester filament. All tanks
associated with the staple operation (south of the main building) have been emptied and cleaned.
7. Analytical Monitoring Notes: See Table 1 for summary of maximum values. The plant monitored
conventional pollutants and total toxic organics (TTO) annually during the previous permit term. The
only test result above detection limits was methylene chloride in the sample from SDO B in 2006 (just
above detect). [Methylene chloride is a very common lab contaminant, and given no'other detects at this
site, contamination is the likely explanation.] Note the facility sampled for ammonia (not part of the SW
sampling parameters). According to the application, facility only sampled for TN and TP 2 times (instead
of 4 like the others).
8. Qualitative Monitoring Notes: Summary not provided (requested by reviewer). Additional info. provided
sample inspection form.
9. Compliance Notes: None related to stormwater.
Page 3 of 6

Table 1: Analytical Monitoring - MAXIMUM Recorded Values as Reported on EPA Form 2C
Sample Date
Total Flow
(MG)
Precipitation
(in)
Duration
(hours)
BOD5
TSS
Ammonia
pH
O&G
TTO*
TN
TP
Benchmark:
30 mg/L
Benchmark:
100 mg/L
Benchmark:
7.2 mg/L
Benchmark:
6-9 mg/L
Benchmark:
30 mg/L
Benchmark:
1 mg/L
Benchmark:
30 mg/L
Benchmark:
2 mg/L
Stormwater Outfall A
N/A - Max
1.041
4
5
0.37
5.9 - 6.6
< 5.0
see notes
0.37
0.046
2/13/2008
0.280
0.7
20.83
2
5
-
6.3
< 5.0
see DMR
0.19
0.046
. Stormwater Outfall B `
N/A - Max
0.300
4
9
0.79
7.0 - 7.7
< 5.0
see notes
0.79
0.053
2/13/2008
0.081
0.7
20.83
2
7
-
7.5
< 5.0
see DMR
0.41
0.031
Stormwater Outfall C
N/A - Max
0.565
4'
111
0.69
I 4.9 - 5.4
< 5.0
see notes
0.69
0.2
2/13/2008
0.152
0.7
20.83
2
56
-
1 4.9
< 5.0
see DMR
0.65
0.2
Stormwater Outfall D
N/A - Max
0.088
4
9
0.88
6.2 - 6.7
< 5.0
see notes
0.88
0.17
2/13/2008
0.024
0.7
20.83
2
8
-
6.3
< 5.0
see DMR
0.44
0.17
Stormwater Outfall 5
N/A - Max
0.653
-
9
27
2.5
6.4 - 7.0
< 5.0
see notes
2.5
0.37
2/13/2008
0.176
0.7
20.83
7
27
-
6.6
< 5.0
see DMR
1.1
0.37
Over Current Benchmark *Total Toxic Organics - Some compounds may be a concem below 1 mg/I; see review of analysis results.
Data Not Collected 1
L
f t-
For comparison, 2008 sample results shown above with maximum values recorded over last permit period.
Maximum from four (4) samples.
Stormwater Factsheet
Page 4 of 6

NC0004944
•
Permit Recommendations: Analytical Monitoring:
Reviewer recommends maintaining most parameters except Total Toxic Organics (TTO). None of the
concentrations indicates a problem, and the methylene chloride detect was likely attributable to laboratory
contamination (the benchmark of 110 mg/I is also far above 2.1 µg/1.) Ammonia was not required by the
permit, and based on sampled concentrations, reviewer does not see necessity to add it as a parameter to the
stormwater monitoring. Removing flow monitoring (no longer routinely required in stormwater permits).
The raw materials include ethylene glycol, terephthalic acid, and fiber finish lubricants. Renewal permit
retains BOD and TSS at all outfalls because appropriate indicators for stormwater pollution from the
industrial activities and chemicals (including ethylene glycol, which exerts high BOD) stored here. Replacing
Oil and Grease with TPH, or total petroleum hydrocarbons, as measured by Method 1664-A (SGT-HEM). TPH
targets petroleum -based hydrocarbons (rather than including animal and vegetable based greases and oils).
The parameter is the same as what is now required for vehicle maintenance areas; the TPH benchmark is 15
mg/1 (instead of 30 mg/1).
Permit retains pH monitoring, especially since some values were below the benchmark range of 6-9 SU.
Permit retains Total Nitrogen (TN) and Total Phosphorus (TP) at all outfalls because discharge is to the
nutrient sensitive High Rock Lake watershed. However, past monitoring from four samples indicate levels
may not be of concern. Recommend discontinuing nutrient monitoring after four more samples.
Monitoring frequency will change to semi-annually through the permit term, and qualitative monitoring will
coincide with analytical sampling events. Introducing tiered response structure to benchmark
exceedances to be consistent with current stormwater individual permits.
Discussions with permit contact: 1/25/2010 Steve Lamb, 704-636-6000 (ext. 4862):
1. Q: Has there been a final decision about the groundwater remediation system?
a. ANSWER: Responsibility is with Celanese in Dallas, TX. Regardless, would not affect
stormwater discharges.
2. Q: Are there any sources of zinc at this facility or in its activities?
a. ANSWER: Cooling water treatment system may have zinc; blowdown discharges to WWTP.
NPDES permit allows toxicity testing in lieu of zinc or copper limits (per NC Action Level
policy). • •
3. Q: What is stored where on site? (Numbers on site plan are pretty small; verify location of ethylene glycol
tanks, etc.)
a. ANSWER: Glycol tank farm is at the back of the plant, near the railroad tracks. These all
drain to a stormwater diverter system, which routes the first flush to the head works of the
WWTP, and after 20 minutes or so, routes the rest to the polishing ponds (middle of
wastewater treatment). SDO 5 is part of that system, so there's hardly ever a discharge
there without treatment, except in a very large storm event that would cause it to overflow
(2/13/08 sample? May not have been diverted. Advised that sampling for this SDO not
required unless it does not go to the WWTP.)
NPDES Stormwater Permit materials reviewed and recommended changes in draft permit prepared by:
Bethany A. Georgoulias
DWQ Stormwater Permitting Unit
January 27, 2010
Page 5 of 5

Grzyb, Julie
. From: [e-mail]
Sent: Tuesday, July 13, 2010 8:55 AM
To: Grzyb, Julie
Subject: re NC0004944, Performance Fibers
EPA has no comments on this draft permit.
1

North Carolina ) ss
Mecklenburg County)
The Charlotte Observer Publishing Co.
Charlotte, NC
Affidavit of Publication
THE CHARLOTTE OBSERVER
DINA SPRINKLE
NCDENR/DWO/POINT SOURCE BRANCH
1617 MAIL SERVICE CENTER
RALEIGH NC 27699
REFERENCE: 30063432
6483319 npdes perform. fiber
Before the undersigned, a Notary Public of said
County and State, duly authorized to administer
oaths affirmations, etc., personally appeared,
being duly sworn or affirmed according to law,
doth depose and say that he/she is a
representative of The Charlotte Observer
Publishing Company, a corporation organized and
doing business under the laws of the State of
Delaware, and publishing a newspaper known as The
Charlotte Observer in the city of Charlotte,
County of Mecklenburg, and State of North Carolina
and that as such he/she is familiar with the
books, records, files, and business of said
Corporation and by reference to the files of said
publication, the attached advertisement was
inserted. The following is correctly copied from
the books and files of the aforesaid Corporation
and Publication.
PUBLISHED ON: 07/10
AD SPACE: 62 LINE
FILED ON: _ 07/15/10
NAME:
TITLE:
DATE:
In Testimony Whereof I have hereunto set my hand and affixed my seal, the
day and year aforesaid.
Public Notice
North Carolina Environmental Management Commission/
NPDES Unit
1617 Mail Service Center
Raleigh, NC 27699.1617 •
Notice of Intent to Issue a NPDES Wastewater Permit
The North Carolina Environmental Management Commission pro-
poses to issue a NPDES wastewater discharge permit to the per-
sons) listed below.
Written comments regarding the proposed permit will be accept-
ed until 30 days after the publish date of this notice. The Director
of the NC Division of Water Duality (DWO) may hold a public hear.
log should there be a significant degree of public interest. Please
mail comments and/or information requests to DWO at the above
address. Interested persons may visit the DWO at 512 N.
Salisbury Street, Raleigh, NC to review information on file.
Additional information on NPDES permits and this notice may be
found on our website: www.nrwaterquality.org, or by calling (919)
807-6304.
The Town of Maiden_requested renewal of permit NC0039594 for W
me Town of Maiden WTP in Catawba County; this permitted dis-
charge is treated domestic/industrial wastewater to Clark Creek.
Catawba River Basin.
Performance Fibers requested renewal of permit NC0004944 for
its Salisbury facility in Rowan County this permitted discharge is
treated domestic and industrial wstewater to North Secbrd
Creek. Yadkin -Pee Dee River Basin.
LP648:i319
Nota
icy Commission Expires May 17, 2R11
Commission Expires: _/_/_

Grzyb, Julie
From: LAMB, STEVE [[e-mail]]
Sent: Wednesday, January 06, 2010 3:32 PM
To: Grzyb, Julie
Cc: CASNER, DAVID
Subject: Possibly spam: Performance Fibers NPDES NC0004944
Julie
We have looked at the TSS data for our site for the past two years and we are concerned. I have attached two TSS
graphs that cover the period from January 2008 through November 2009.
160
140
120
, 100
80
60
40
20
0
TSS (Monthly avg)
•
4
11
-i�----='-=5-• -
,
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". - .-
... "I
iQ
7
' --ai-
-CA--
.11-
5-.Nu-+�-
1 3 5 7 9 11 13 15 17 19 21 23
168
400
350
300
250
200
150
100
50
0
TSS (Daily Max)
1\4N
y
1 3 5 7 9 11 13 15 17 19 21 23
340
Process Capability at 3 sigma =
Process Capability at 3 sigma =
As we discussed last month, our plant will have trouble meeting the Monthly Average limit. During the past two
years our plant would have been out of compliance about 13 % of the time. Our TSS is a result of the algae
growth in our polishing ponds during the summer months. We have used copper sulfate to control the algae but
are always concerned about the possibility of having a toxicity problem due to the copper sulfate addition. Our
process capability for TSS Monthly Average is 168 but the new proposed limit is 120. This will cause us a
problem.
i

We have had several meetings with plant operations personnel to discuss this potential problem. We have not
been able to develop a lot of "inexpensive" solutions. Ideally we would eliminate our polishing ponds but that
is very expensive.
Our plant has always expected nothing but full compliance with all regulations. Our plant history of being
100% compliant has been very good. We don't want this to change and can not afford to spend a lot of money
in the current economic environment.
I would like to ask that the state establish our new limit at our Process Capability of 168. Is this possible?
Sincerely
Steve Lamb
Environmental Manager
Disclaimer: This e-mail communication and any attachments may contain confidential and privileged
information and is for use by the designated addressee(s) named above only. If you are not the intended
addressee, you are hereby notified that you have received this communication in error and that any use
or reproduction of this email or its contents is strictly prohibited and may be unlawful. If you have
received this communication in error, please notify us immediately by replying to this message and
deleting it from your computer. Thank you.
2

Grzyb, Julie
From: Grzyb, Julie
Sent: Thursday, January 07, 2010 9:19 AM
To: 'LAMB, STEVE'
Subject: RE: Performance Fibers NPDES NC0004944
Steve,
Would like to discuss this in more detail. Please call me at 919-807-6389 (office) or on my cell at 336-210-8454.
Today (Thurs.), I will be out of the office between 10 am and 2 PM. This afternoon it would be best to reach me on my
cell. Tomorrow)tI will be back in the office. j
Thanks, Wier p J"j �JV�'t .j 1.f�- _' :i:�w+ �0�VI,/ jr CVG r j1�r_w.' t+� +j'•.
Julie {~
From: LAMB, STEVE [mailto:[e-mail]]
Sent: Wednesday, January 06, 2010 3:32 PM
To: Grzyb, Julie
Cc: CASNER, DAVID
Subject: Possibly spam: Performance Fibers NPDES NC0004944
Julie
We have looked at the TSS data for our site for the past two years and we are concerned. I have attached two TSS
graphs that cover the period from January 2008 through November 2009.
160
140
120
4, 100
80
= 60
40
20
0
TSS (Monthly avg)
.
7\
-
i.
y1 „
\
;\
!
__ \-A\
3 5
I I I
9 11 13 15 17 19 21 23
168
Process Capability at 3 sigma =
1

400
350
300
250
. 200
= 150
100
50
0
TSS {Daily Max)
•
I
I
1
r
I I
1
I
I
1
I
1
II
I
I
I
II
!
I
I
7
5 7 9 1 '1 13 15 17 19 21 23
340
Process Capability at 3 sigma =
As we discussed last month, our plant will have trouble meeting the Monthly Average limit. During the past two
years our plant would have been out of compliance about 13 % of the time. Our TSS is a result of the algae
growth in our polishing ponds during the summer months. We have used copper sulfate to control the algae but
are always concerned about the possibility of having a toxicity problem due to the copper sulfate addition. Our
process capability for TSS Monthly Average is 168 but the new proposed limit is 120. This will cause us a
problem.
We have had several meetings with plant operations personnel to discuss this potential problem. We have not
been able to develop a lot of "inexpensive" solutions. Ideally we would eliminate our polishing ponds but that
is very expensive.
Our plant has always expected nothing but full compliance with all regulations. Our plant history of being
100% compliant has been very good. We don't want this to change and can not afford to spend a lot of money
in the current economic environment.
I would like to ask that the state establish our new limit at our Process Capability of 168. Is this possible?
Sincerely
Steve Lamb
Environmental Manager
Disclaimer: This e-mail communication and any attachments may contain confidential and privileged
information and is for use by the designated addressee(s) named above only. If you are not the intended
addressee, you are hereby notified that you have received this communication in error and that any use
or reproduction of this email or its contents is strictly prohibited and may be unlawful. If you have
received this communication in error, please notify us immediately by replying to this message and
deleting it from your computer. Thank you.
2

Grzyb, Julie
From: Georgoulias, Bethany
Sent: Wednesday, January 27, 2010 9:54 AM
To: Grzyb, Julie
Cc: Bennett, Bradley
Subject: Performance Fibers
Attachments: NC0004944 SW Permit Text Modified for Renewal.docx; NC0004944_SPU_Review.docx
Hi Julie,
Attached are my review notes and documentation (feel free to extract what you need for your staff report request — I
just used our template SRR), and the permit text with the stormwater section through the end modified (starts on page
7).
The renewal requirements include most of the same parameters, except TTO, which I don't think is necessary. There is
also 'total petroleum hydrocarbons' (TPH) instead of O&G, which targets petroleum based oils (O&G includes veg and
animal fats). Our permits have been incorporating TPH for vehicle maintenance areas because it's a better target for
motor oil, and the method 1664-A (SGT-HEM) is the same that can be used for O&G analysis, there's just an extra step.
In other words, it is less expensive than the GC -based lab analysis done for TPH that some folks may be more familiar
with, which we do not require for SW. The method is specified in the permit.
I have also (1) incorporated the tier structure and other updates to SPPP requirements, definitions, etc.; (2) removed
redundant sections; (3) moved some things around to suit the format; (4) added a few other sections I thought needed
to be there; (5) other changes to make it consistent with our current permits (no more flow requirement, etc.). I
retained the annual reporting requirement, even though monitoring will now be semi-annual. We'd done this recently
in a general permit.
This is a nice format for stormwater requirements in the WW NPDES permit. **I did highlight places where you'll need
to check that the Part/Section reference is correct. I just wasn't sure about those.** If you guys like it, I'll share with the
rest of my unit for future combo permits.
The only thing I think we need to make sure they understand is that they are not responsible for monitoring SDO 5
unless it does not go through the diverter system. It sounds like in most every circumstance, all that flow will be
diverted to the WWTP and ultimately subject to the sampling of your outalls.
Just let me know if you have any questions! I'll work on the annual DMR reporting form when you prepare it for
issuance; just give me about a week's notice.
Bg
Bethany Georgoulias
Environmental Engineer
NCDENR I DWQ I Stormwater Permitting Unit
1617 Mail Service Center, Raleigh, NC 27699-1617
512 N. Salisbury St, Raleigh, NC 27604
Phone: [phone]
Fax: [phone]
NEW Website: http://portal.ncdenr.orq/web/wg/ws/su
E-mail correspondence to and from this address may be subject to the North Carolina Public
Records Law and may be disclosed to third parties.
1

November 10, 2009
Bethany,
Performance Fibers NPDES permit (NC0004944) is up for renewal. It has one outfall for process
wastewater and five outfalls for stormwater discharges. When the permit was last issued we simply
added a Section B with Limitations and Controls for stormwater Discharges.
The facility manufactures polyester in chip and fiber form and is subject to 40 CFR 414.30 and 414.40
(OCPSF federal guidelines). Primary raw materials include terephthalic acid, ethylene glycol, and fiber
finish oils. They are trying to close the groundwater remediation site, no discharge is occurring at this
time. Production is down so the actual discharge flow is about .466 MGD (our records show a three year
avg. of 0.0472 MGD, Aug. 2006- Aug. 2009).
The application submitted contains annual analytical results from all 5 stormwater outfalls. Is it possible
someone in your group can review this and supply me with an updated Section B for stormwater?
Please let me know how you would like to proceed with this. Attached are copies of the existing permit
and application. If you have any questions for Performance Fibers my contact at the facility is Steve
Lamb at 704-636-6000 ext. 4862 or email: [e-mail]
Thanks,
Julie Grzyb
76389

' Grzyb, Julie
From: Georgoulias, Bethany
Sent: Monday, November 23, 2009 2:47 PM
To: Grzyb, Julie
Subject: RE: Performance Fibers - NC0004944
Julie,
r I also noticed that for this permit in BIMS, there is no way to tell it also has stormwater. Could we add the stormwater
outfalls in there as well? I would do it myself, but I don't have permission to modify this permit applications in BIMS (I
I guess they restrict access for me to just stormwater permits). We're trying to do a better job keeping track of which
permits you all have over there that incorporate SW requirements as well, so this will help.
If you need help walking through the way we do it, I'll be glad to help. Typically we just enter one outfall to record the
receiving waterbodies (they don't enter our data in BIMS, so we usually do not enter multiple outfalls — just the lat/lon
for the general site location and other info.). Here we have all the coordinates for specific outfalls and could add each of
them for this permit.
Thanks!
Be any Georgoulias
Environmental Engineer
NCDENR I DWQ ( Stormwater Permitting Unit
1617 Mail Service Center, Raleigh, NC 27699-1617
512 N. Salisbury St, Raleigh, NC 27604
Phone: [phone]
Fax: [phone]
Website: http://h2o.enr.state.nc.us/su
E-mail correspondence to and from this address may be subject to the North Carolina Public
Records Law and may be disclosed to third parties.
From: Georgoulias, Bethany
Sent: Monday, November 23, 2009 2:25 PM
To: Grzyb, Julie
Subject: RE: Performance Fibers - NC0004944
Julie,
It looks like the company submitted EPA forms for renewals... have you by any chance forwarded these other forms that
we typically send out with our SW NCS renewals to them? (I think I sent them for the Charlotte -Douglas airport a while
back, so maybe you thought of this already, but they are attached.)
Also, do you have an electronic copy of the previous permit I could work with? I like the template and would love to
have something like that to craft all future combo SW-WW permits off of, plus it will be easier for you to cut and paste
our sections into your final permit.
Thanks!
Bg
Bethany Georgoulias
Environmental Engineer
NCDENR I DWQ I Stormwater Permitting Unit
1

•
Y•'
1617 Mail Service Center, Raleigh, NC 27699-1617
512 N. Salisbury St, Raleigh, NC 27604
Phone: [phone]
Fax: [phone]
Website: http://h2o.enr.state.nc.us/su
E-mail correspondence to and from this address may be subject to the North Carolina Public
Records Law and may be disclosed to third parties.
From: Grzyb, Julie
Sent: Friday, November 13, 2009 8:40 AM
To: Georgoulias, Bethany
Subject: RE: Performance Fibers - NC0004944
If you can finish it by than, that would be great, otherwise the next deadline is two weeks out from 12/7/09.
Thanks,
Julie
From: Georgoulias, Bethany
Sent: Friday, November 13, 2009 8:24 AM
To: Grzyb, Julie
Cc: Belnick, Tom
Subject: RE: Performance Fibers - NC0004944
Okay, thanks Julie. I think that should be doable, but if not, I'll speak to Bradley early next week about a lead on it. Our
NCG02 Mining renewal permit needs to be finalized around the same time, but Jen Jones is ramping back up on working
on that, so it shouldn't be a problem for me to devote time to this one. -Bg
Bethany Georgoulias
Environmental Engineer
NCDENR I DWQ I Stormwater Permitting Unit
1617 Mail Service Center, Raleigh, NC 27699-1617
512 N. Salisbury St, Raleigh, NC 27604
Phone: [phone]
Fax: [phone]
Website: http://h2o.enr.state.nc.us/su
E-mail correspondence to and from this address may be subject to the North Carolina Public
Records Law and may be disclosed to third parties.
From: Grzyb, Julie
Sent: Thursday, November 12, 2009 4:51 PM
To: Georgoulias, Bethany
Cc: Belnick, Tom
Subject: RE: Performance Fibers - NC0004944
Bethany,
The permit has already expired but realistically I am hoping to get it Public Notice on December 9th which means it
should done on the 7th or sooner.
I like how this was set-up as well and agree some sort of template would make it easier on both Sections.
Also, I went to Charlotte Douglas International Airport last week and will try to send you my notes. Lots going on
...construction wise, Jimmy was not clear on which storm drains would remain in time. He needs to do a fair amount of
work to get his application straight.
Julie
2

• From: Georgoulias, Bethany
Sent: Thursday, November 12, 2009 4:39 PM
To: Grzyb, Julie
Cc: Bennett, Bradley
Subject: Performance Fibers - NC0004944
Hi Julie,
Thanks for bringing the package by my office and info. about this combined NPDES WW & SW permit renewal. I'll be
glad to work on it with you. Can you give me a timeframe for your renewal schedule? I won't be able to take a look
through the materials they submitted until next week at the earliest, but it does appear the SW section will need a lot of
updating. Do you know who in NPDES and in our group may have worked on this one back in 2006? It's a very neat
integration of the two sections — it occurs to me that we should maybe come up with a "template" SW/WW NPDES
permit for when these come up.
I'll be able to plan better if I know when you'll need a draft permit ready by.
Thanks so much!
Bg
Bethany Georgoulias
Environmental Engineer
NCDENR I DWQ I Stormwater Permitting Unit
1617 Mail Service Center, Raleigh, NC 27699-1617
512 N. Salisbury St, Raleigh, NC 27604
Phone: [phone]
Fax: [phone]
Website: http://h2o.enr.state.nc.us/su
E-mail correspondence to and from this address may be subject to the North Carolina Public
Records Law and may be disclosed to third parties.
3

Grzyb, Julie
From: LAMB, STEVE [Steve.Lamb©performancefibers.com]
Sent: Friday, November 13, 2009 1:35 PM
To: Grzyb, Julie
Subject: Salisbury NPDES Permit
Julie
I believe we will be able to meet the BOD and TSS limits that we discussed this morning. Our waste flow has been up
during the past several of months but that is probably due to the increased rain fall.
I would like to make sure that our mailing address is changed. We have had a PO for 40 years but decided to drop it and
go with local mail delivery. Our mailing address is the same as our site address:
Performance Fibers Operations
7401 Statesville Blvd
Salisbury, NC 28147
If you need anything else then please call.
Thanks
Stephen Lamb
Environmental Section Leader
Office: 704-636-6000 (ext 4862)
Disclaimer: This e-mail communication and any attachments may contain confidential and privileged
information and is for use by the designated addressee(s) named above only. If you are not the intended
addressee, you are hereby notified that you have received this communication in error and that any use
or reproduction of this email or its contents is strictly prohibited and may be unlawful. If you have
received this communication in error, please notify us immediately by replying to this message and
deleting it from your computer. Thank you.
i

November 10, 2009
Bethany,
Performance Fibers NPDES permit (NC0004944) is up for renewal. It has one outfall for process
wastewater and five outfalls for stormwater discharges. When the permit was last issued we simply
added a Section B with Limitations and Controls for stormwater Discharges.
The facility manufactures polyester in chip and fiber form and is subject to 40 CFR 414.30 and 414.40
(OCPSF federal guidelines). Primary raw materials include terephthalic acid, ethylene glycol, and fiber
finish oils. They are trying to close the groundwater remediation site, no discharge is occurring at this
time. Production is down so the actual discharge flow is about .466 MGD (our records show a three year
avg. of 0.0472 MGD, Aug. 2006- Aug. 2009).
The application submitted contains annual analytical results from all 5 stormwater outfalls. Is it possible
someone in your group can review this and supply me with an updated Section B for stormwater?
Please let me know how you would like to proceed with this. Attached are copies of the existing permit
and application. If you have any questions for Performance Fibers my contact at the facility is Steve
Lamb at 704-636-6000 ext. 4862 or email: [e-mail]
Thanks,
Julie Grzyb
76389

SOC PRIORITY PROJECT: No
To: Western NPDES Program Unit
Water Quality Section
Attention: Dina Sprinkle
Date: October 23, 2008
NPDES STAFF REPORT AND RECOMMENDATIONS
County: Rowan
NPDES Permit No.: NC0004944
PART I - GENERAL INFORMATION
1. Facility and address: Performance Fibers Operations, Inc.
7401 Statesville Boulevard
Salisbury, N.C. 28145
2. Date of investigation: October 21, 2008
3. Report prepared by: Samar Bou-Ghazale, Environmental Engineer II
4. Person contacted and telephone number: Stephen Lamb, [phone], ext. 4862.
5. Directions to site: From the jct. of US Hwy. 70 and Hwy. 801 �1.5 miles west of the
Town of Cleveland, travel east on US Hwy. 70 0.2 mile. The entrance to the KOSA
plant will be on the right (south) side of US Hwy. 70.
6. Discharge point(s), List for all discharge points: -
Latitude: 35° 42' 40"
Longitude: 80° 36' 10"
Attach a USGS Map Extract and indicate treatment plant site and discharge point on map.
USGS Quad No.: E 16 NE
7. Site size and expansion area consistent with application: Yes.
8. Topography (relationship to flood plain included): Gently rolling, 3-6% slopes. Portions
of the site may be at or near the 100year flood plain elevation.
9. Location of nearest dwelling: Approx. 1000+ feet from the WWTP site.

Page Two
10. Receiving stream or affected surface waters: North Second Creek
a. Classification: C
b. River Basin and Subbasin No.: Yadkin 030706
c. Describe receiving stream features and pertinent downstream uses: Fed by a large
drainage basin, the receiving stream has good flow and a well defined channel
(60-70 feet wide x 1-2 feet deep). Downstream uses are mostly agriculture.
PART II - DESCRIPTION OF DISCHARGE AND TREATMENT WORKS
1. a. Volume of wastewater: 2.305 MGD (Design Capacity)
Sources of Wastewater*
1. Sanitary 0.049 MGD
2. Finish 0.057 MGD
3. Boilers/Chillers 0.047 MGD
4. Bandcaster 0.057 MGD
5. Cooling Tower 0.095 MGD
6. Process 0.057 MGD
7. Groundwater 0.0 MGD
8. Stormwater 0.051 MGD
9. WTP Blowdown 0.053 MGD
Total Average Flow 0.466 MGD
The Total average flow shows a reduction to 0.466 MGD from 1.385 MGD in
2004. Also, according to Mr. Lamb, the groundwater remediation system was
shut down in compliance with the EPA requirements.
b. What is the current permitted capacity: 2.305 MGD
c. Actual treatment capacity of current facility (current design capacity): 2.305 MGD
d. Date(s) and construction activities allowed by previous ATCs issued in the
previous two years: There have been no recently issued ATCs.
e. Description of existing or substantially constructed WWT facilities: The existing
WWT facilities specifically serving the domestic waste stream at this facility
consist of a comminutor and chlorine contact chamber. From there, all domestic
wastewater then flows into a lift station where it is pumped into the existing
aeration basins.

Page Three
The process water treatment facilities consist of a bar screen followed by a grit
chamber, two (2) covered equalization tanks, two (2) aeration basins, two (2)
secondary clarifiers, four (4) polishing ponds (one out of service), an aerobic
digester, sludge filter press, sludge holding tank, ferric chloride tank, lime tank,
and instrumented flow measurement.
f. Description of proposed WWT facilities: There are no WWT facilities proposed at
this time.
g.
Possible toxic impacts to surface waters: This facility has a generally good record
of passing their toxicity test. There were no failures during the past 5year cycle.
2. Residual handling and utilization/disposal scheme: Residuals generated in the treatment
process are dewatered on -site with the filter press and then disposed of by Waste
Management at the Rowan County Landfill.
3. Treatment plant classification: Class IV (no change from previous rating).
4. SIC Code(s): 2821, 2824 Wastewater Code(s): 36, 14, 02, 66, 21, 73
5. MTU Code(s): 02502
PART III - OTHER PERTINENT INFORMATION
1. Is this facility being constructed with Construction Grant Funds or are any public monies
involved (municipals only)? No public monies were used in the construction of this
facility.
2. Special monitoring or limitations (including toxicity) requests:
a. Performance Fibers is requesting that copper not be limited, the waiving of the In -
stream monitoring and sampling of the storm water outfalls using grab samples. It
should be noted that all of the above requests have been previously granted.
3. Important SOC/JOC or Compliance Schedule dates: N/A
4. Alternative Analysis Evaluation: There is no known alternative available that is capable
of treating the amount of effluent produced by this facility.

Page Four
PART IV - EVALUATION AND RECOMMENDATIONS
The permittee, Performance Fibers Operation, Inc., has requested renewal of the subject
permit.
Performance Fibers has taken one aeration basin and one secondary clarifier out of
service due to a decrease in waste loading as mentioned above. Also, the groundwater
remediation system was shut down permanently in compliance with EPA requirements. Mr.
Lamb. Was advised to copy this office on the agreement that has been reached with EPA for the
closure of the groundwater remediation system.
Stormwater first flush goes to the aeration basin. After the first flush the stormwater
discharge is directed to a polishing pond.
The existing WWTP appeared in good condition during the site investigation.
Pending review and approval by the Western NPDES Program Unit, it is recommended that
the permit be renewed as requested.
d -
Water Quality Regional Supervisor
/v f Z S /p f
Date

Performance r. Fibers
September 19, 2008
CERTIFIED MAIL
7007 3020 0002 5035 9870
Dina Sprinkle
NC DENR / DWQ / Point Source Branch
1617 Mail Service Center
Raleigh, NC 27699-1617
Subject: Performance Fibers Operations, Inc.
Salisbury Permit Renewal
NPDES Permit # NC0004944
Rowan County
RECEIVED
S E P 1 8 2008
DENR - WATER QUALITY
POINT SOURCE BRANCH
Dear Dina:
Performance Fibers Operations, Inc. owns and operates a polyester manufacturing facility
in Salisbury, North Carolina. Process wastewater and stormwater is discharged to North
Second Creek in accordance with National Pollutant Discharge Elimination System
(NPDES) Permit Number NC0004944, which expires March 31, 2009. Three copies of
this letter and the attached permit application are being submitted for renewal of the
NPDES Permit. This letter provides an overview of the Performance Fibers Operations,
Inc. Salisbury facility, and Attachment A includes the permit renewal application.
I. Facility Location
The Performance Fibers Operations, Inc. facility is located on the south side of U.S.
Highway 70 approximately 4 miles west of Salisbury, North Carolina, near the
intersection of Highway 70 and State Highway 801. The facility's location is presented
on Figure 1 in Attachment A, which also shows nearby transportation routes and surface
waters.
II. Plant Overview
Performance Fibers Operations, Inc. manufactures polyester in the form of chip and fiber
at its Salisbury, North Carolina, facility. Primary raw materials in these manufacturing
processes include terephthalic acid, ethylene glycol, and fiber finish lubricants (see
Figure 2 in Attachment A). Process wastewater, groundwater, sanitary wastewater,
P.O. BOX 4 1 7401 STATESVILLE BLVI). I I-l'Y. 70 WEST I S.1I ISBURY, NC 28147
uvou'.performnncefibrrs.rom

Performance r. Fibers
cooling tower blowdown, and water treatment plant blowdown are treated onsite before
being discharged to North Second Creek.
Wastewater treatment consists of coarse solids removal (bar screen), equalization,
biological treatment (activated sludge), and clarification, followed by a series of
polishing ponds, as presented on Figure 3 in Attachment A. Waste biological sludge is
aerobically digested and dewatered. Dewatered solids are disposed of off -site by Waste
Management, Inc. at the local Rowan County Landfill.
The ground water remediation program at the site has been shutdown during a trial period
with EPA approval. Future operation of the pump -and -treat remediation is unlikely but
the final decision as to whether or not to operate the pump -and -treat system has not been
made. When this remediation system is operating the water is treated in the waste
treatment plant. Recovered groundwater from the interior system contains primarily
ethylene glycol and is anaerobically pretreated before being discharged to the
equalization tank for treatment in the WWTP. Recovered groundwater from the
perimeter system contains 1,4-dioxane as the major pollutant and is discharged through
the polishing ponds to Outfall 001 to North Second Creek.
The plant discharges storm water associated with industrial activity through five
stormwater outfalls (A,B,C,D and 5) as presented on Figure 1 in Attachment A.
Stormwater Outfall #5 collects stormwater from the main manufacturing areas of the site,
where spills are more likely or chemicals are stored. Outfall #5 collects stormwater from
a system of diverter weirs that route dry weather spills and the first flush of storm water
runoff to either the WWTP headworks or Number 2 Polishing Pond. As the storm water
volume increases in the diverter system, flow continues to be discharged to either the
WWTP or Number 2 polishing pond with the excess water that overflows the diverter
weirs being discharged directly to North Second Creek. All five storm water outfalls are
monitored according to the NPDES permit and the Stormwater Pollution Prevention Plan.
Information on the storm water outfalls is provided on the EPA Form 2C.
III. Additional Data
The Salisbury site is trying to collect additional storm water samples for review and
V application submittal. There has not been sufficient rain during the past several weeks to
collect the samples. When these additional samples have been analyzed, we will submit a
revision to EPA FORM 2C (Effluent Data) in Attachment A.
IV. Historical Data Review
Outfall 001
P.U. BOX 4 1 7401 STATESVILLE BLVD. 1 HWY. 70 WEST 1 S:.l.ISBURY, NC 28147
www.performancefibers.com

Performance F. Fibers
Historical daily data from the Discharge Monitoring Reports (DMRs) were reviewed for
the past two years (May 1, 2006 through May 31, 2008). Annual DMR data for the
Organic Chemicals, Plastics, and Synthetic Fibers (OCPSF) priority pollutants for the
past 5 years (2004 through 2008) were reviewed. The review indicated that no OCPSF
chemicals were detected and the daily discharge limits were well within permit limits.
Storm Water (Outfalls A, B, C, D, and 5)
Performance Fibers collects storm water samples annually for analysis of conventional
parameters as well as total toxic organics (TTO). The only test result that was above
detection limits was methylene chloride (75-09-2) in Outfall B in 2006. The detection
limit for methylene chloride was 2.0 ug/1 and the result was 2.1 ug/l, which is very close
to the detection limit. We do not believe this result indicates the presence of this
substance in the outfall B.
Flow
The average effluent (Outfall 001) flow has decreased from the 2003 permit renewal
period. The decrease has been caused by a reduction in production levels, shutdown of
the ground water remediation extraction wells, and the continued drought conditions in
North Carolina. The average daily effluent flow for the past two years is 0.470 MGD
(million gallons per day) compared to a permit limit of 2.305 MGD.
Chronic Toxicity
The site is required to test the effluent (Outfall 001) for chronic toxicity 4 times per year
using ceriodaphnia dubia as the test organism. The permit requires no observable
inhibition of reproduction or significant mortality at an effluent concentration of 34
percent. There were no failures during the past 5 year cycle.
V. pH Adjustment
The effluent (Outfall 001) pH is adjusted during periods of high algae bloom in the
polishing ponds using sulfuric acid.
VI. Copper Sulfate Addition
Copper sulfate is added to polishing ponds # 3 and #4 to control algae growth during the
warm summer months. This is shown on Figure 3.
P.O. BOX 4 I 740I STATESVILLE BLVD 1 HWY. 70 WEST I SALISBURY, NC 28147
www.performancefibcrs.com

Performance f . Fibers
VII. Yadkin/Pee Dee River Basin Association
The Salisbury site has been a member in good standing of the Yadkin Pee Dee River
Basin Association for the past 10 years. The Salisbury site has agreed to membership for
the next 5 year NPDES cycle for the river basin. The DWQ memo verifying the site's
membership and waving the in -stream sampling requirements is attached in Attachment
B.
VIII. Plant Modification
Performance Fibers has taken one aeration basin out of service due to the decrease in
waste loading over the past year. C-basin has been decommissioned by shutting off all
influent flow and physical removal of the residual sludge. The Salisbury plant continues
to use Aeration Basin A and Aeration Basin B and does not plan to restart aeration basin
C. This change was communicated to the DENR office in Mooresville in 2007.
IX. Sludge Management Plan
Performance Fibers does not have a Sludge Management Plan. Waste biological sludge
is aerobically digested and dewatered. Dewatered solids are disposed of off site by
Waste Management in the local Rowan County Landfill.
X. Proposed Limits
Metals
Copper sulfate is added periodically as an algaecide to the polishing ponds. The plant
currently does not have a copper limit and copper is regulated via the chronic toxicity
test. Two consecutive failures of the chronic toxicity test would trigger copper limits.
Performance Fibers Operations, Inc. believes this copper control to be sufficient and does
not feel that a copper limit based on the Action Level is required.
Other metals such as zinc, iron, and manganese are well within the North Carolina limits.
Waiving of In -stream Monitoring
The Salisbury Site requests the waiving of in -stream monitoring requirements as a result
of the site's membership and involvement with the Yadkin Pee Dee River Basin
Association.
P.O. BOX 4 I 7401 STATESVILLE BLVD. I HWY. 70 WEST I SALISBURY, NC 28147
u'u'm.performancefibers.com

Performance F. Fibers
Stormwater Outfall Sampling
The state has always allowed the site to collect Stormwater samples using grab sampling
techniques instead of composite samplers. The outfalls are located remote from the
manufacturing area where electrical power is not available. The Salisbury plant would
like to continue sampling the stormwater outfalls using grab samples.
XI. Contact
If you have any questions or require additional information, please contact myself or
Stephen Lamb at [phone] (extension 4862).
Sincerely,
Anthony J. ranecky
Operations Director
Enclosures:
Attachment A — Permit Application
Attachment B — DWQ Memo — Yadkin Pee Dee River Basin Association
Attachment C — 2008 Lab Data
P.O. BOX 4 1 7401 STATESVILLE BLVD. I HWY. 70 WEST I SALISBURY, NC 28147
www.performancefibers.com

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Figure 1
Facility Location
SallPlant

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Terephthalic
Acid (TA)
Ethylene
Glycol
Finish
Lubricants
Polyester Manufacturing Operation
Polymer
Production
•
Polymer
Production
Chip
Production
t
Filament
Production
Product to
Customers
(potential)
Wastewater
t
Product to
Customers
Wastewater
to
Treatment
Raw Material / Product Figure 2
Performance Fibers Operations, Inc.
Salisbury Plant

gi
Sanitary
Waste
Process
Waste
Solid Waste
To Landfill 1
Comminutor
Cooling Tower
Blowdown
PWP
Chlorine Contact
Bar Screen
Grit Removal
i
1
1
1
1
1
1
1
1
1
1
1
Equalization
Blowdown
Pumped Lift
Station
Anaerobic
Pretreatment
•
•
Anaerobic
Pretreatment
Aeration Basin "A"
Aeration Basin "C"
Out -of -service
Aeration Basin "B"
Storm Water (from plant areas)
Outfall # 5 ►
Return Activated Sludge
Solids to
Landfill
-•-•-• ... •-•-•-•.
•
Interior Groundwate
Recovery System
Sludge Dewatering
Perimeter GW
Recovery System
Equalization
r
Direct
Discharge
Polishing Pond # 1
Out of Service
Polishing Pond # 2
Polishing Pond # 3
Polishing Pond # 4
U / V Peroxide
•
1
Outfall
001
Copper
Sulfate
Addition
Acid Metering
(Sulfuric)
-' Figure 3
----_-_--._._._._._._._._._.-._._._._._ •-._._._._._._._•-•-•-•-• Salisbury Waste Treatment
Remediation Equipment that is turned off S.C. Lamb, 8/15/2008
ref: WWTP, Flow Diagram.PPT