NC0002305_Authorization to Construct_20030105

NPDES DOCUMENT SCANNING; COVER SHEET
NPDES Permit:
NC0002305
Guilford Mills WWTP
Document Type:
Permit Issuance
Wasteload Allocation
Authorization to Construct (AtC)
�
Permit Modification
Complete File - Historical
Engineering Alternatives (EAA)
Correspondence
Owner Name Change
Instream Assessment (67b)
Speculative Limits
Environmental Assessment (EA)
Document Date:
January 5, 2003
Thins document is printed oa reuse paper - ignore any -
content on the reverse side

GUILFORD
GUILFORD MILLS, I N C. • G R E E N S B O R O, NC
F
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47(5
P.O. Box 26969 • Greensboro, NC 27419-6969 • [phone]
January 5, 2003
NCDENR, Division of Water Quality
1617 Mail Service Center
Raleigh, NC 27699-1617
Subject: Engineer's Certification
Alum/ Caustic Dispensing System
Guilford Mills, Inc. — Guilford East Plant
NPDES Permit ATC002305AO1
Kenansville, Duplin County, North Carolina,
Dear Sir or Madam,
Enclose please find the Engineer's Certification for subject system, dated 2/3/03.
As required, the Wilminton Regional Office was notified at least 48 hours in advance of start-up.
This notification was made in a telephone call to Steve West on 1/30/03.
Please call me at [phone] if you have any questions or need additional information.
Since
Paul R. Bruesch, P.E.
Corporate Environmental Manager
cc: Brent Turner, Wayne Berry
Greg Hughey, AT&E
George House, Brooks, Pierce, McClendon
Steve West, DWQ-Wilmington Regional Office
H:\documents\Word1NC Plants\Guilford East\Ltr NCDENR DWQ Engineers Cert Alum System 020503.doc

ENGINEER'S CERTIFICATION
for
CONSTRUCTION of GROUNDWATER TREATMENT FACILITIES
I, Gregory R. Hughey, am a duly registered Professional Engineer in the state of North Carolina
and have been authorized to periodically observe the construction of the subject project for the
Permittee.
Project: Guilford Mills — East Mill, Duplin County
Alum/Caustic Dispensing System
Installation and Startup
Located: NC Highway 11
north of Kenansville, North Carolina
Duplin County
ATC Number
NPDES Number
Incident Number
Contractor's Number
ATC002305A01
NC0002305
Project consisting of installation, startup testing, and subsequent design -adjustment oversight of:
• a 10,000-gallon fiberglass tank for alum storage
• a 10,000-gallon fiberglass tank for caustic storage
• secondary containment for both surface tanks and product lines
• dual dispensing pumps (for redundancy) for alum feed [105 gph @ 50 psig (max)]
• dual dispensing pumps (for redundancy) for caustic feed [105 gph @ 50 psig (max)]
• pump control auto switch -over system with auditory and visual alarms (GE series 90-30 PLC)
• valves, gauges, piping and other appurtenances constructed of materials appropriate for the product
• all related structures, equipment, conduit, electrical wiring and controls, and other appurtenances as
specified in the approved design documents.
I hereby certify that I did periodically observe this project with due care and diligence and that
the construction was completed in substantial conformance with the Authorization to Construct
and with the approved plans and specifications.
Signature Registration No. 0 Z35 cL Z
Date 2 • -3 . 03 ,, ��H CARo''
The Division of Water Quality hereby ' • a SEAL
khoWledgg8 rapt and acceptance of -
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Michael F. Easley, Govemor
State of North Carolina
William G. Ross, Jr., Secretary
Department of Environment and Natural Resources
Alan W. Klimek, PE, Director
Division of Water Quality
August 20, 2002
Paul R. Bruesch, PE
Corporate Environmental Manager
Guilford Mills, Inc.
P.O. Box 26969
Greensboro, NC 27419-6969
Subject: Approval for Authorization to Construct (ATC)
Alum/Caustic Dispensing System
NPDES Permit ATC002305AO1
Guilford Mills — East Plant
Duplin County
Dear Mr. Bruesch:
The Division of Water Quality (DWQ) has reviewed your drawings and specifications submitted May 1, 2002 for
the proposed construction of an alum/caustic feed system at the subject site. The Division hereby grants
Authorization to Construct these facilities, described herein.
DWQ understands that this dispensing system is proposed to provide automatic control for dispensing alum
[Al2(SO4)3] to remove solids from wastewater effluent, and for dispensing caustic soda (NaOH) to control pH.
Your application details the calculations and specifications for:
• a 10,000-gallon fiberglass tank for alum storage
• a 10,000-gallon fiberglass tank for caustic storage
• secondary containment for both surface tanks and product lines
• dual dispensing pumps (for redundancy) for alum feed [105 gph @ 50psi (max)]
• dual dispensing pumps (for redundancy) for caustic feed [105 gph @ 50psi (max)]
• pump control auto switch -over system with auditory and visual alarms (CyboCon, Model CCCE-02)
• valves, gauges, piping and other appurtenances constructed of materials appropriate to the product.
This ATC is issued in accordance with Part III, Paragraph A of NPDES Permit NC0002305 effective August 1,
1998, and shall be subject to revocation unless the wastewater treatment facilities are constructed according to the
conditions and limitations specified in that permit. In the event that the facilities fail to perform satisfactorily,
including the creation of nuisance conditions, the Permittee shall take immediate corrective action, including
those as may be required by this Division, such as the construction of additional or replacement wastewater
treatment or disposal facilities.
Notification Requirements. The Permittee shall notify the Wilmington Regional Office, telephone number
[phone], at least forty-eight (48) hours in advance of start-up of the installed facilities, so that an in -
place inspection can be made. Such notification to the regional supervisor shall be made during the normal office
hours of 8:00 a.m. until 5:00 p.m. on Monday through Friday, excluding state holidays.
Engineer's Certification. Upon completion of construction and prior to operation startup, the Permittee shall
provide to the Division a written certification from a North Carolina -certified professional engineer that the
permitted facility has been installed in accordance with the NPDES Permit, this Authorization to Construct, and
the approved plans and specifications (see attached form).
AVA
NCDENR
North Carolina Division of Water Quality 1617 Mail Service Center Raleigh, NC 27699-1617 [phone] Customer Service
1 800 623-7748

Guilford Mills, Inc.
Guilford Mills -- East Plant
ATC0022305 AO1
Page 2
Mail Engineer's Certification to:
NCDENR / DWQ / NPDES Unit
1617 Mail Service Center
Raleigh, North Carolina 27699-1617
Operator Requirements. The Permittee shall employ a certified wastewater treatment plant Operator in
Responsible Charge (ORC) of the wastewater treatment facilities. The operator must hold a certificate of the type
and grade at least equivalent to, or greater than, the classification assigned to the wastewater treatment facilities
by the Certification Commission. The Permittee must also employ a certified back-up operator of the appropriate
type and grade to comply with the conditions of Title 15A, Chapter 8G, .0200. The facility's ORC must visit each
Class I facility at least weekly, and each Class II, III, and IV facility at least daily, excluding weekends and
holidays. The ORC must properly manage and document daily operation and facility maintenance by complying
with all conditions of Title 15A, Chapter 8G, 0200.
Additional Conditions. The Operational Agreement between the Permittee and the Environmental Management
Commission is incorporated herein by reference and is a condition of this Permit. Noncompliance with the terms
of the Operational Agreement shall subject the Permittee to all sanctions provided by G. S. 143-215.6 for
violation of, or failure to act in accordance with, the terms and conditions of this Permit.
Failure to abide by the requirements contained in this Authorization to Construct may subject the Permittee to an
enforcement action by the Division of Water Quality in accordance with North Carolina General Statute 143-
215.6A to 143-215.6C. The issuance of this Authorization to Construct does not preclude the Permittee from
complying with any and all statutes, rules, regulations, or ordinances which may be imposed by other government
agencies (local, state, and federal) having jurisdiction.
The Permittee shall maintain a copy of the approved plans and specifications on file for the life of the
facility. One (1) copy of the approved plans and specifications is enclosed for your records. If you have questions
about this Authorization to Construct, or if we can be of further service, please contact Joe Corporon at
[[e-mail]] or call [phone], extension 597.
Respectfully,
Alan W. Klimek, PE.
Enclosure: Approved ATC Application for ATC002305AO1 including plans and specifications
Engineer's Certification Form
cc: Central Files (cover letter only)
Wilmington Regional Office, Water Quality Section (cover letter only)
NPDES Unit$(letter only)
Point Source Compliance and Enforcement Unit (cover letter only)
AT&E. Attn: Greg Hughey. PE, 545 Panorama Road,
Earlysville, Virginia. 22936 (cover letter; Engineer's Certification Form)

MEMORANDUM
DATE: June 11, 2002
TO: Joe Corporon
NPDES Unit
Point Source Branch, WQ
THROUGH: Rick Shiver
Water Quality Re Yonal Supervisor
FROM: Mike Williams
Environmen Specialist
SUBJECT: Authorization to Construct
Guilford Mills, Inc.
NPDES Permit NC0002305
ATC No. 0002305 A01
Duplin County
U
J U N 1 2 2002
1
5
CER - WATER QUALITY
POUT SOURCE BRANCH
Attached please find the staff report, and topographical map of the subject facility.
Guilford Mills requests the upgrade of the 1.5 MGD WWTP Facility by construction and
installation of a 10,000 gallon alum storage tank, a 10,000 gallon caustic tank, pH controls
and appurtenances to reduce solids in the effluent. The Company has had difficulty
meeting a 27% effluent toxicity limit due to what is believed to be the heavy use of
polymers. The use of polymers was temporarily suspended in November 2001. Since that
time the Company has experienced violations of the permitted BOD limit due to high solids
content in the effluent. The Company believes that the use of alum will settle solids to the
point where both BOD and toxicity limitations may be met.
It is recommended that an authorization to construct be issued to Guilford Mills as
soon as possible so that the Company may proceed with the construction of the necessary
improvements to achieve compliance with the permit limitations.
If you have any questions concerning this report, please advise.
MW:guilford.ATC
cc: Kevin Bowden- ATU
Wilmington Regional Office

SOC PRIORITY PROJECT: Yes
If Yes, SOC No. WQ 01-011
To: Permits and Engineering Unit
Water Quality Section
Attention: Joe Corporon
(Review Engineer)
Date: June11, 2002
AUTHORIZATION TO CONSTRUCT # 002305A01
NPDES PERMIT
REPORT AND RECOMMENDATIONS
County: Duplin
Permit No. NC0002305
PART I - GENERAL INFORMATION
I. Facility and Address: Guilford Mills, Inc.
P.O. Box 26969
Greensboro, North Carolina 27419-6969
2. Date of On -Site Investigation (if conducted): June 10, 2002
3. Report Prepared by: Mike Williams
4. Contact Persons and Telephone Number: Paul Bruesch [phone]
Brent Turner [phone]
5. Verified Discharge Point(s), List for all discharge points:
Latitude: 350058 Longitude: 785100
Attach a USGS map extract and indicate treatment facility site and discharge point
on map.
USGS Quad No: G27SE USGS Quad Name: Albertson, NC
6. Site size and expansion area consistent with application ?
X Yes No If No, explain:
7. Topography (relationship to flood plain included): Site elevation is approximately 30
ft. amsl, sloping to a wetland of approximately 20 ft. amsl, and not prone to flooding.

8. Location of nearest dwelling: No residential dwellings within 1000 ft.
PART II - DESCRIPTION OF DISCHARGE AND TREATMENT WORKS
1. Existing treatment facility
a. What is the permitted flow limit? 1.50 MGD
b. What is the flow capacity approved by previous Authorizations to Construct?
1.50 MGD.
c. What is the actual design treatment capacity of the existing facility? 1.5 MGD
d. What construction activities were approved by Authorizations to Construct issued
in the past two (2) years and what are the dates of these authorizations: None.
e. Please provide a description of existing or substantially constructed wastewater
treatment facilities: Influent bar screen, parshall flume, aerated flow equalization,
dual mechanical aeration basins, polymer addition, dual clarifiers, aerobic
digester, sludge thickener, sludge drying beds, flow metering device, and
automated samplers.
2. Please provide a description of proposed wastewater treatment facilities: Installa
tion of a 10,000 gallon reinforced fiberglass above ground alum storage tank for
coagulation, a 10,000 gallon reinforced fiberglass above ground caustic storage
tank, containment structure, associated pumps and piping, and pH monitors for the
purpose of chemical coagulation to enhance solids removal in the system. The
Company has had difficulty meeting BOD and toxicity limits. Polymers were
determined to cause toxicity problems. During early November 2001 polymer use
was suspended. Recently, the use of polymers was reinstated to a lesser degree
to aid in BOD reduction, while remaining at a satisfactory effluent toxicity value. The
Company will install the above mentioned tanks and hope to request a future A to
C for construction of a tertiary clarifier unit.
3. Residuals handling and utilization/disposal scheme;
a. If residuals are being land applied, please specify DWQ Permit No:
WQ0018107 Synagro
Telephone No: 336-766-0328
b. Residuals stabilization: Class B pathogen reduction
c. Landfill: No

d. Other disposal/utilization scheme (Specify): McGill Environmental- Permit
No.WQ0006816- Class A — Sludge is mixed with mulch.
4. Treatment plant classification : Class III
5. SIC Code(s): 2259
Wastewater Code(s): Primary 55 Secondary 2,14
Main Treatment Unit Code: 05005
6. Important SOC, JOC or Compliance Schedule dates:
Submission of Pians and Specifications:
Begin Construction:
Complete Construction:
PART III - EVALUATION AND RECOMMENDATIONS
Dates
5/1/02
9/1/02
2/1/03
4/46-5
It is recommended that an authorization to construct be issued to Guilford Mills for the
construction of the chemical feed system consisting of an alum storage tank, a caustic
storage tank, pH controls and other appurtenances to control solids in the effluent. It has
been determined that the company has had difficulty meeting toxicity without polymer
addition. When polymer use was suspended, BOD limits were violated. Testing has shown
that the BOD levels corresponded to higher solids values, and therefore the Company is
working to reduce solids by utilizing alum.
Signature of Report Preparer
6at/1cZ
e
IAA �--�A A r1 0 G, i t- 0 2
Water Quality Regional Supervisor Date