NC0004405_Permit (Modification)_20050506

NPDES DOCIMENT SCANNING COVER SHEET
NC0004405
NPDES Permit:
Document Type:
Permit Issuance
Wasteload Allocation
Authorization to Construct (AtC)
Permit Modification`
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Complete File - Historical
Correspondence
Speculative Limits
Instream Assessment (67b)
Environmental Assessment (EA)
Permit
History
Document Date:
May 6, 2005
This document is printed on reuse paper - more any
conterit on the reverse side

Michael F. Easley, Governor
William G. Ross Jr., Secretary
North Carolina Department of Environment and Natural Resources
Alan W. Klimek, P.E. Director
Division of Water Quality
May 6, 2005
Arthur Toompas
Cone Denim LLC
2420 Fairview St.
Greensboro, North Carolina 27405
Subject NPDES Permit Modification
Permit NC0004405
Cliffside Plant WWTP
Formerly Cone Textile Group
Rutherford County
Dear Mr. Toompas:
Division personnel have reviewed and approved your request to transfer ownership of the subject permit,
received on May 3, 2005. This permit modification documents the change in ownership.
Please find enclosed the revised permit. All other terms and conditions contained in the original permit remain
unchanged and in full effect. This permit modification is issued under the requirements of North Carolina. General
Statutes 143-215.1 and the Memorandum of Agreement between North Carolina and the U.S. Environmental
Protection Agency.
If you have any questions concerning this permit modification, please contact the Point Source Branch at (919)
733-5083, extension 363.
Sincerely,
Alan W. Klimek, P.E.
cc: Central Files
Asheville Regional Office, Water Quality Section
Aquatic Toxicology Unit
NPDES Unit File
No Carolina
/7aturally
North Carolina Division of Water Quality 1617 Mail Service Center Raleigh, NC 27699-1617 Phone [phone] Customer Service
Internet: h2o.enr.state.nc.us 512 N. Salisbury St. Raleigh, NC 27604 FAX [phone] I-877-623-6748

Permit NC0004405
141
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,
Cone Denim LLC
is hereby authorized to discharge wastewater from a facility located at the
Cliffside Plant
US Highway 221-A and NCSR 1003
Cliffside
Rutherford County
to receiving waters designated as Second Broad River in the Broad River Basin
in accordance with effluent limitations, monitoring requirements, and other conditions set
forth in Parts I, II, III and IV hereof.
This permit shall become effective May 6, 2005.
This permit and authorization to discharge shall expire at midnight on July 31, 2008.
Signed this day May 6, 2005.
01- Alan W. Klimek, P.E., Director
Division of Water Quality
By Authority of the Environmental Management Commission

A
Permit NC0004405
SUPPLEMENT TO PERMIT COVER SHEET
All previous NPDES Permits issued to this facility, whether for operation or discharge are hereby
revoked. As of this permit issuance, any previously issued permit bearing this number is no longer
effective. Therefore, the exclusive authority to operate and discharge from this facility arises under the
permit conditions, requirements, terms, and provisions included herein.
Cone Denim, LLC
is hereby authorized to:
1. Continue to operate an existing 1.75 MGD wastewater treatment plant consisting of:
• Pump station and bar screen
• Extended aeration basin
• Dual final clarification
• Aqua disk filter
• Chlorination, effluent reaeration, and dechiorination
• Sludge storage tank
The facility is located at the US Highway 221-A and NCSR 1003, Cliffside, Rutherford
County.
2. Discharge wastewater from said treatment works at the location specified on the
attached map into the Second Broad River which is classified C waters in the Broad
River Basin.

Cone Denim LLC
State Grid/Quad: Chesnee
Receiving Stream: Second Broad River
Stream Class: C
Latitude:
Longitude:
Drainage Basin:
Sub -Basin:
35° 13' 59" N
81* 45' 59" W
Broad River
03-08-02
Facility Location
not to scale
NPDFS Permit No. NC0004405
eekingliaraCettety-

4
Permit NC0004405
A. (1.) EFFLUENT LIMITATIONS AND MONITORING REQUIREMENTS — FINAL
During the period beginning on the effective date of this permit and lasting until expiration, the
Permittee is authorized to discharge from outfall 001. Such discharges shall be limited and
monitored by the Permittee as specified below:
EFFLUENT
CHARACTERISTICS
Limits
_
Monitoring Requirements
Monthly
Average
Dairy'
Masfmum
t
Fze+gaeacy
_
Sample Type
Sample
Locationl
Flow
1.75 MGD
Continuous
Recording
I or E
BOD, 5-day (20°C)
1,080 lbs/day
2,460 lbs%day
3/Week
Composite
E
COD
13,576
lbs/day
31,746
lbs/day
3/Week
Composite
E
Total Suspended Solids
2,745 lbs/day
6,329 lbs/day
3/Week
Composite
E
Fecal Coliform (geometric
mean)
200/100 ml
400/100 ml
_
3/Week
Grab
E
Total Residual Chlorine
28 }pg/L
3/Week
Grab
E
Temperature
3/Week
Grab
E
Total Nitrogen
Quarterly
Composite
E
Total Phosphorus
Quarterly
Composite
E
pH3
3/Week
Grab
E
Sulfide
22.8 Ibs/day
52.8 lbs/day
Weekly
Grab
E
Phenols
28.1 lbs/day
45 lbs/day
Weekly
Grab
E
Total Chromium
28.1 lbs/day
45 lbs/day
Weekly
Composite
E
Total Copper
2/Month
Composite
.
E
Total Zinc
2/Month
Composite
E
Chronic Toxicity
Quarterly
Composite
E
Notes:
1. Sample Locations: E- Effluent, I- Influent
2. For a given wastewater sample, TN TKN + NO3-N + NO2-N, where TN is total nitrogen, TKN is total
Kjeldahl Nitrogen, and NO3-N and NO2-N are nitrate and nitrite nitrogen, respectively.
3. The pH shall not be less than 6.0 standard units nor greater than 9.0 standard units.
4. Chronic toxicity (Ceriodaphnia) P/F at 4.2 %; January, April, July and October.
There shall be no discharge of floating solids or visible foam in other than trace amounts.

Permit NC0004405
A. (2.) CHRONIC TOXICITY PERMIT LIMIT (QRTRLY)
The effluent discharge shall at no time exhibit observable inhibition of reproduction or significant
mortality to Ceriodaphnia dubia at an effluent concentration of 4.2 %.
The permit holder shall perform at a minimum, auarterli monitoring using test procedures outlined
in the "North Carolina Ceriodaphnia Chronic Effluent Bioassay Procedure," Revised February 1998, or
subsequent versions or "North Carolina Phase II Chronic Whole Effluent Toxicity Test Procedure"
(Revised -February 1998) or subsequent versions. The tests will be performed during the months of
January, April, July and October. Effluent sampling for this testing shall be performed at the NPDES
permitted final effluent discharge below all treatment processes.
If the test procedure performed as the first test of any single quarter results in a failure or ChV below
the permit limit, then multiple -concentration testing shall be performed at a minimum, in each of the
two following months as described in "North Carolina Phase II Chronic Whole Effluent Toxicity Test
Procedure" (Revised -February 1998) or subsequent versions.
The chronic value for multiple concentration tests will be determined using the geometric mean of
the highest concentration having no detectable impairment of reproduction or survival and the
lowest concentration that does have a detectable impairment of reproduction or survival. The
definition of "detectable impairment," collection methods, exposure regimes, and further statistical
methods are specified in the "North Carolina Phase II Chronic Whole Effiuent Toxicity Test
Procedure" (Revised -February 1998) or subsequent versions.
All toxicity testing results required as part of this permit condition will be entered on the Effluent
Discharge Monitoring Form (MR-1) for the months in which tests were performed, using the
parameter code TGP3B for the pass/fail results and THP3B for the Chronic Value. Additionally, DWQ
Form AT-3 (original) is to be sent to the following address:
Attention: NC DENR / DWQ / Environmental Sciences Branch
1621 Mail Service Center
Raleigh, North Carolina 27699-1621
Completed Aquatic Toxicity Test Forms shall be filed with the Environmental Sciences Branch no
later than 30 days after the end of the reporting period for which the report is made.
Test data shall be complete, accurate, include all supporting chemical/physical measurements and
all concentration/response data, and be certified by laboratory supervisor and ORC or approved
designate signature. Total residual chlorine of the effluent toxicity sample must be measured and
reported if chlorine is employed for disinfection of the waste stream.
Should there be no discharge of flow from the facility during a month in which toxicity monitoring is
required, the permittee will complete the information located at the top of the aquatic toxicity (AT)
test form indicating the facility name, permit number, pipe number, county, and the month/year of
the report with the notation of "No Flow' in the comment area of the form. The report shall be
submitted to the Environmental Sciences Branch at the address cited above.
Should the permittee fail to monitor during a month in which toxicity monitoring is required,
monitoring will be required during the following month.
Should any test data from this monitoring requirement or tests performed by the North Carolina
Division of Water Quality indicate potential impacts to the receiving stream, this permit may be re-
opened and modified to include alternate monitoring requirements or limits.
NOTE: Failure to achieve test conditions as specified in the cited document, such as minimum
control organism survival, minimum control organism reproduction, and appropriate environmental
controls, shall constitute an invalid test and will require immediate follow-up testing to be completed
no later than the last day of the month following the month of the initial monitoring.