NC0025984_Permit Issuance_20031215

Michael F. Easley, Governor
State of North Carolina
William G. Ross, Jr., Secretary
Department of Environment and Natural Resources
Alan W. Klimek, P.E., Director
Division of Water Quality
December 15, 2003
Mr. Scott Hoyle
Director of Public Works
Town of Forest City
P.O. Box 728
Forest City, North Carolina 28043
Subject: Issuance of NPDES Permit NC0025984
Forest City WWTP
Rutherford County
Dear Mr. Hoyle:
Division personnel have reviewed and approved your application for renewal of the subject
permit. Accordingly, we are forwarding the attached NPDES discharge permit. This permit is issued
pursuant to the requirements of North Carolina General Statute 143-215.1 and the Memorandum of
Agreement between North Carolina and the U.S. Environmental Protection Agency dated May 9,1994
(or as subsequently amended).
The following modifications have been made to the final permit:
> The mercury limit was incorrectly applied in the draft permit. There were no detections of
mercury (all values < 0.2 µg/L) from January 2001 through August 2003. Therefore, the limit
has been removed and monitoring reduced to twice per month.
➢ Weekly average limits for Total Cyanide and Total Lead have been removed since the acute
daily maximum limits are more stringent. You will still be required to meet daily
maximum limits for both parameters.
In response to your questions/comments on the draft permits:
> Monitoring data from January 2001 to the present showed a reasonable potential to exceed
water quality standards for lead. This potential was determined by applying an EPA
statistical method that multiplies your highest detected value (130 µg/L) by a variance factor
(5.45), which is derived from actual monthly data. The result (708 µg/L) represents a highest
potential effluent concentration. This potential value is then compared to an allowable
discharge concentration (138 µg/L). In this case, the highest potential effluent concentration is
much greater than the allowable value. In addition, the maximum detected value (130 µg/L)
is much greater than the EPA acute criterion of 34 µg/L. If your monitoring results continue
to show lead levels below the detection level over the next 6 months, you may request to have
the lead limit removed from your NPDES permit.
> Monitoring data showed two occasions where the allowable cyanide concentration was
exceeded. On May 2, 2002 your facility reported a value of 770 µg/L and on October 2, 2002
you reported a value of 97 µg/L. Since there is reasonable potential to exceed the water
quality standard, we cannot remove the effluent limit.
North Carolina Division of Water Quality
1617 Mail Service Center
Raleigh, North Carolina 27699-1617
[phone]
FAX [phone]
On the Internet at http://h2o.enr.state.nc.us/

Issuance of Permit NC0025984
Page 2
➢ Monitoring data showed three occasions where there was reasonable potential to exceed silver
water quality standards. Silver has an action level standard, therefore you will not receive an
effluent limit unless you fail your WET tests and silver is identified to be the cause. However,
since there is reasonable potential to exceed the water quality standard, we cannot reduce the
monitoring requirement.
> The requirement to conduct conductivity monitoring is being removed from 100% domestic
wastewater permits. Monitoring must remain for industrial dischargers and domestic
dischargers that have a pretreatment program.
If any parts, measurement frequencies or sampling requirements contained in this permit are
unacceptable to you, you have the right to an adjudicatory hearing upon written request within thirty
(30) days following receipt of this letter. This request must be in the form of a written petition,
conforming to Chapter 150B of the North Carolina General Statutes, and filed with the Office of
Administrative Hearings (6714 Mail Service Center, Raleigh, North Carolina 27699-6714). Unless such
demand is made, this decision shall be final and binding.
Please note that this permit is not transferable except after notice to the Division. The Division
may require modification or revocation and reissuance of the permit. This permit does not affect the
legal requirements to obtain other permits which may be required by the Division of Water Quality or
permits required by the Division of Land Resources, the Coastal Area Management Act or any other
Federal or Local governmental permit that may be required.
If you have any questions concerning this permit, please contact Ms. Toya Fields at telephone
number [phone], extension 551.
Sincerely,
ORIGINAL SIGNED BY
Tom Belnick
Alan W. Klimek, P.E.
cc: Central Files
Asheville Regional Office/Water Quality Section
NPDES Unit
Aquatic Toxicology Unit
Madolyn Dominy / EPA

Permit NC0025984
STATE OF NORTH CAROLINA
DEPARTMENT OF ENVIRONMENT AND NATURAL RESOURCES
DIVISION OF WATER QUALITY
PERMIT
TO DISCHARGE WASTEWATER UNDER THE
NATIONAL POLLUTANT DISCHARGE ELIMINATION SYSTEM
In compliance with the provision of North Carolina General Statute 143-215.1, other lawful standards
and regulations promulgated and adopted by the North Carolina Environmental Management
Commission. and the Federal Water Pollution Control Act, as amended. the
Town of Forest City
is hereby authorized to discharge wastewater from a facility located at the
Forest City Wastewater Treatment Plant
397 Riverside Drive
Forest City
Rutherford County
to receiving waters designated as the 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.
The permit shall become effective January 1, 2004.
This permit and the authorization to discharge shall expire at midnight on July 31, 2008.
Signed this day December 15, 2003.
ORIGINAL SIGNED BY
Tom Belnick
Alan W. Klimek, P.E., Director
Division of Water Quality
By Authority of the Environmental Management Commission

Permit NC0025984
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.
The Town of Forest City is hereby authorized to:
1. Continue to operate an existing 4.95 MGD wastewater treatment facility that
includes the following components:
a Influent screening
❑ Grit and grease removal
❑ Primary and secondary aeration
❑ Secondary clarification
❑ Chlorination
❑ Dechlorination
❑ Sludge thickening
❑ Sludge digestion
❑ Belt press
❑ Sludge drying
This facility is located at the Forest City Wastewater Treatment Plant (397
Riverside Drive, Forest City) in Rutherford County.
2. Discharge from said treatment works at the location specified on the attached
map into the Second Broad River, currently a class WS-IV stream in the Broad
River Basin.

Quad: Gastonia NC0025984
Subbasin: 30802
Latitude: 35'19'38" Forest City WWTP
Longitude: 81°50'25"
Receiving Stream: Second Broad River
Stream Class: WS-IV

Permit NC0025984
A. (1) EFFLUENT LIMITATIONS AND MONITORING REQUIREMENTS
Beginning on January 1, 2004 and lasting until expiration, the Permittee is authorized to discharge
treated wastewater from Outfall 001. Such discharges shall be limited and monitored by the Permittee
as specified below:
PARAMi✓ i t:R
EFFLUENT LIMITATIONS
MONITORING REQUIREMENTS
Monthly
Average
Weekly
Average
Daily
Maximum
Measurement
Frequency
Sample
Type
Sample
Location'
Flow
4.95 MGD
Continuous
Recording
Influent or Effluent
BOD5, 20°C2
25.5 mg/L
38.25 mg/L
Daily
Composite
Influent, Effluent
Total Suspended Solids2
30.0 mg/L
45.0 mg/L
Daily
Composite
Influent, Effluent
NH3-N
10.0 mg/L
30.0 mg/L
3/Week
Composite
Effluent
Dissolved Oxygen3
Daily
Grab
Effluent
Fecal Colrform
(geometric mean)
200/100 ml
400/100 ml
Daily
Grab
Effluent
pH
Between 6 0 and 9.0 standard units
Daily
Grab
Effluent
Total Residual Chlorine
28 µg/L
Daily
Grab
Effluent
Temperature, °C
Daily
Grab
Effluent
Total Nitrogen
Quarterly
Composite
Effluent
Total Phosphorus
Quarterly
Composite
Effluent
Chronic Toxicity
J
Quarterly
Composite
Effluent
Total Cyanide
22 µg/L
Weekly
Grab
Effluent
Total Lead
Pfbr 34 p.g/L
Weekly
Composite
Effluent
Total Copper
2/Month
Composite
Effluent
Total Mercury
2/Month
Composite
Effluent
Phenols
PF`t'
2/Month
Grab
Effluent
Total Silver
'WV
2/Month
Composite
Effluent
r.r,r .'., s-
Dissolved Oxygen
Add
v„,• ,rt.
Variables
Grab
Downstream
Fecal Coliform
(geometric mean)
Variables
Grab
Upstream,
Downstream
ConductivityVariables
Grab
Upstream,
Downstream
Temperature
Variables
Grab
Upstream,
Downstream
Footnotes:
1 Upstream: Upstream 50 feet from outfall. Downstream: 50 feet upstream of the J.C. Cowan
discharge point
2 The monthly average effluent BOD5 and total suspended solids concentrations shall not exceed
15% of their respective influent value (85% removal).
3 The daily average dissolved oxygen effluent concentration shall not be less than 6.0 mg/L.
4 Chronic Toxicity (Ceriodaphnia) P/F at 18%; samples shall be collected quarterly during the
months of January, April, July, and October. See condition A. (2).
5 Instream sampling shall be conducted 3/week during June, July. August and September and
1 /week during the rest of the year.
There shall be no discharge of floating solids or visible foam in other than trace amounts.

Permit NC0025984
A. (2) CHRONIC TOXICITY PERMIT LIMIT (Quarterly)
The effluent discharge shall at no time exhibit observable inhibition of reproduction or significant
mortality to Ceriodaphnia dubia at an effluent concentration of 18%.
The permit holder shall perform at a minimum, quarterlti monitoring using test procedures outlined in
the "North Carolina Ceriodaphnia Chronic Effluent Bioassay Procedure," Revised February 1998, or
subsequent versions or "North Carolina Phase II Chronic Whole Effluent Toxicity Test Procedure"
(Revised -February 1998) or subsequent versions. The tests will be performed during the months of
January, April, July and October. Effluent sampling for this testing shall be performed at the
NPDES permitted final effluent discharge below all treatment processes.
If the test procedure performed as the first test of any single quarter results in a failure or ChV below
the permit limit, then multiple -concentration testing shall be performed at a minimum, in each of the
two following months as described in "North Carolina Phase II Chronic Whole Effluent Toxicity Test
Procedure" (Revised -February 1998) or subsequent versions.
The chronic value for multiple concentration tests will be determined using the geometric mean of the
highest concentration having no detectable impairment of reproduction or survival and the lowest
concentration that does have a detectable impairment of reproduction or survival. The definition of
"detectable impairment," collection methods. exposure regimes. and further statistical methods are
specified in the "North Carolina Phase II Chronic Whole Effluent Toxicity Test Procedure" (Revised -
February 1998) or subsequent versions.
All toxicity testing results required as part of this permit condition will be entered on the Effluent
Discharge Monitoring Form (MR-1) for the months in which tests were performed, using the parameter
code TGP3B for the pass/fail results and THP3B for the Chronic Value. Additionally, DWQ Form AT-3
(original) is to be sent to the following address:
Attention: North Carolina Division of Water Quality
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.

Permit NC0025984
A. (3) EFFLUENT POLLUTANT SCAN
The Permittee shall perform an annual Effluent Pollutant Scan for all parameters listed in the attached table. The
analytical methods shall be in accordance with 40 CFR Part 136 and shall be sufficiently sensitive to determine
whether parameters are present in concentrations greater than applicable standards and criteria. Samples shall
represent seasonal variations. Unless otherwise indicated. metals shall be analyzed as "total recoverable."
Ammonia (as N) Trans-1,2-dichloroethylene Bis (2-chloroethyl) ether
Chlorine (total residual, TFC) 1,1-dichloroethylene Bis (2-chloroisopropyl) ether
Dissolved oxygen 1,2-dichloropropane Bis (2-ethylhexyl) phthalate
NitrateiNitrite 1,3-dichloropropylene 4-bromophenyl phenyl ether
Kjeldahl nitrogen Ethylbenzene Butyl benzyl phthalate
Oil and grease Methyl bromide 2-chloronaphttralene
Phosphorus Methyl chloride 4-chlorophenyl phenyl ether
Total dissolved solids Methylene chloride Chrysene
Hardness 1,1,2,2-tetrachloroethane Di-n-butyl phthalate
Antimony Tetrachloroethylene Di-n-octyl phthalate
Arsenic Toluene Dibenzo(a,h)anthracene
Beryllium 1,1,1-trichloroethane 1,2-dichlorobenzene
Cadmium 1,1,2-trichloroethane 1,3-dichlorobenzene
Chromium Trichloroethylene 1,4-dichlorobenzene
Copper Vinyl chloride 3,3-dichlorobenzidine
Lead Acid -extractable compounds: Diethyl phthalate
Mercury P-chloro-m-creso Dimethyl phthalate
Nickel 2-chlorophenol 2,4-dinitrotoluene
Selenium 2,4-dichlorophenol 2,6-dinitrotoluene
Silver 2,4-dimethylphenol 1,2-diphenylhydrazine
Thallium 4,6•dinitro-o-cresol Fluoranthene
Zinc 2,4-dinitrophenol Fluorene
Cyanide 2-ndrophenol Hexachlorobenzene
Total phenolic compounds 4-nitrophenol Hexachlorobutadiene
Volatile organic compounds: Pentachlorophenol Hexachlorocyclo-pentadiene
Acrolein Phenol Hexachloroethane
Acrylonitrile 2,4,6-trichlorophenol Indeno(1,2,3-cd)pyrene
Benzene Base -neutral compounds: Isophorone
Bromoform Acenaphthene Naphthalene
Carbon tetrachloride Acenaphthylene Nitrobenzene
Chlorobenzene Anthracene N-nitrosodi-n-propylamine
Chlorodibromomethane Benzidine N-nitrosodimethylamine
Chloroethane Benzo(a)anthracene N-nitrosodiphenylamine
2-chloroethylvinyt ether Benzo(a)pyrene Phenanthrene
Chloroform 3,4 benzofluoranthene Pyrene
Dichlorobromomethane Benzo(ghi)perylene 1,2,4•trichlorobenzene
1,1 •dichloroethane Benzo(k)fluoranthene
1,2-dichloroethane Bis (2-chloroethoxy) methane
Test results shall be reported to the Division in DWQ Form- A MR-PPA1 or in a form approved by the Director
within 90 days of sampling. The report shall be submitted to the following address: Division of Water Quality,
Water Quality Section, Central Files. 1617 Mail Service Center. Raleigh. North Carolina 27699-1617.
A. (4) SPECIAL CONDITION FOR WTP EXPANSION
Upon receiving DEH approval for an expansion of the Forest City Water Treatment Plant above 8 MGD,
Forest City shall notify the Division. At that time the Division may re -open this permit (NC0025984) to
incorporate new limits for conventional parameters and toxicants, reflective of the new Instream Waste
Concentration.

Public Notice
State of North Carolina
Environmental Management Commission / NPDES Unit
1617 Mail Service Center
Raleigh, NC 27699-1617
Notification of Intent to Issue A NPDES Wastewater permit
On the basis of thorough staff review and application of NC General
Statute 143.21, Public law 92-500 and other lawful standards and
regulations, the North Carolina Environmental Management Commission
proposes to issue a National Pollutant Discharge Elimination System
(NPDES) wastewater discharge permit to the person(s) listed below
effective 45 days from the publish date of this notice.
Written comments regarding the proposed permit will be accepted until 30
days after the publish of this notice. All comments received prior to that
date aro considered in the final determinations regarding the proposed
permit. The Director of the NC Division of Water Quality may decide to
hold a public meeting for the proposed permit should the Division receive
a significant degree of public interest.
Copies of the draft permit and other supporting Information on file used to
determine conditions present in the draft permit are available upon request
and payment of the costs of reproduction. Mail comments and/or requests
for information to the NC Division of Water Quality at the above address or
call Ms. Valery Stephens at [phone], extension 520. Please include
the NPDES permit number (attached) in any communication. Interested
persons may also visit the Division of Water Quality at 512 N. Salisbury
Street, Raleigh. NC 27604-1148 between the hours of 8:00 am and 5:00
pm to review information on file.
Riverstone industrial park, Forest City, North Carolina has applied for
renewal of its permit NC 0087084 for its WWTP in Rutherford County.
This permitted facility discharges treated wastewater to the Broad River in
the Broad River Basin. Currently total residual chlorine is water quality
limited. This discharge may affect future allocations in this portion of
the watershed.
Fair Haven Home in Bostic, North Carolina has applied for renewal of its
permit NC 0079448 for its WWTP in Rutherford County. This permitted
facility discharges to Webbs Creek in the Broad River Basin. Currently
total residual choline is water quality limited. This discharge may affect
future allocations in this portion of the watershed.
The Town of Forest City (128 North Powell Street, Forest City, NC 28043)
has applied for renewal of permit NC 0025984 for its WWTP in Rutherford
County. This permitted facility discharges treated wastewater to the
Second Broad River in the Broad River Basin. Currently BOD, ammonia
nitrogen, fecal coliform, total mercury: total lead, total residual chlorine
and cyanide are water quality limited. This discharge may affect future
in this portion of the Broad River Basin.
United World Mission, Union Mills, North Carolina, has applied for
renewal of its permit NC 0032174 for its waste water treatment facility
in Rutherford County discharging to Cherry Creek in the Broad River
Basin. Currently ammonia nitrogen and total residual chlorine are water.
quality limited. This discharge may affect future allocations in this portion
of the watershed.
T OF PUBLICATION
1F NORTH CAROLINA
ERFORD COUNTY
a Notary Public of said County and State,
fied, and authorized by law to administer
d
1THER RHODES
deposes and says: that they are
ivertising Representitive
or other officer or employee authorized to
'HE DAILY COURIER, a newspaper
ered as second class mail In the town of
unty and State; that they are authorized to
)rn statement; that the notice or other legal
of which is attached hereto, was published
Dn the following dates:
ember 12, 2003
l/
1 which such notice, paper, document, or
blished was, at the time of each and every
aper meeting all of the requirements and
1-597 of the General Statutes of North
newspaper within the meaning of Section
3s of North Carolina.
tber, 2003.
,,(Apjei/Ok-be..t.
assliied Advertising Representative
efore me this the 28th day of November,
(Elisa Flynn, Notary Pc)
My commission expires: November 21, 2007

Town of forest City
PO Box72.8
Forest City, MC 8.8043
To: Natalie V. Sierra
NPDES UNIT
From: Scott Hoyle
Director of Public Works
Town of Forest City
Cc: Jeff Dotson
ORC Town of Forest City WWTP
Dear Natalie,
October 23, 2003
OCT 2 8 2003
Based on our draft permit for the Town of Forest City WWTP NC 0025984 we would like to request
you review the following.
• Ammonia — Form January 2001 to present our ammonia results showed a maximum value of 1.85
mg/L We would like to request the sampling frequency be reduced from 3 times per week to
weekly.
• Lead — Questioning weekly monitory and limitation for lead using LTMP data, our data shows
less the detection levels (Data Summaries included with this letter.) The Town of Forest City
WWTP noted a hit of lead on 3/24/03 of 0.130 mg/L. We question how this can be demonstrated
as potential to exceed water quality standards. Please explain.
• Cyanide — From January 2001 to present Forest City had only one sample reported that would
exceed the limit included on the draft permit. The Town of Forest City request that the limit be
changed to "monitor only."
• Conductivity — In a previous conversation with an inspector out of the Asheville Regional Office,
it was mentioned that conductivity was being taken off of new permits. Is this a possibility for the
Town of Forest City? Please explain.
• Mercury — At the bottom of our current limits page (issued in 1998) footnote #5 states, "The
mercury limit will become effective in one year (i.e., December 1, 1999) if weekly monitoring
data indicates a reasonable potential for exceedance of the mercury water quality standard. The
detection limit for mercury is 0.2 ug/L. If the measured levels of mercury are below the detection
limit, then the measurement is considered to be 0 for purposes of compliance evaluation and
should be reported on the DMR as <0.2 ug/L." A letter was written to Mr. Dave Goodrich on July
28, 2000 with data demonstrating no mercury hits within the timeframe. No response was
received from the state on this matter. Since that time we have continued to see values of < 0.2
ug/L. The new detection level from Method 1631 continues to show very low mercury values.
We request that mercury be considered monitor only, and possibly extending sampling frequency
to 2 times per month opposed to current weekly sampling.
The Town of Forest City would greatly appreciate reviewing the matters. We apologize for any delays.
The Town of Forest City WWTP has been training new laboratory, and solids handling staff; as well as the
added time restraints with the new Riverstone Industrial Park WWTP. Should you have an • stions or
comments feel free to contact myself or Jeff Dotson any time concerning this matter.
PO Box 728 Forest City, NC 28043
Scott Ho e
Director of Public Works
Town of Forest City
Telephone [phone] Fax [phone]
Email address: fcwwtparfci.net
Visit our website
www.townofforestcity.com

POTW NAME
FOREST CITY WWTP
'DES/NONDISCHARGE PERMIT #
NC 0025984
SAMPLE LOCATION
EFFLUENT
w Detection Limit Data (BDL) should be marked as "< and the detection limit' i.e. <0
sample date flow
1/5/1999
1/6/1999
1/7/1999
2/9/1999
2/10/1999
2/11/1999
3/23/1999
3/24/1999
3/25/1999
4/27/1999
4/28/1999
4/29/1999
5/25/1999
5/26/1999
5/27/1999
6/29/1999
6/30/1999
7/1/1999
7/27/1999
7/28/1999
7/29/1999
12/14/1999
12/15/1999
12/16/1999
4.163
3.280
3.172
2.958
3.127
3.150
4.172
4.092
3.936
3.577
3 899
4.405
3.974
3.776
3.842
3.941
3.918
3.830
3.691
3.600
3.768
4.507
4.087
4 091
G
C
< 0.05
< 0.05
< 0.05
< 0.05
< 0.05
< 0.05
< 0.05
< 0.05
< 0.05
< 0.05
< 0.05
< 0.05
< 0.005
< 0.005
< 0.005
0.007
< 0.005
< 0.005
< 0.005
< 0.005
< 0.005
0.0065
< 0.005
< 0.005
0.13
0.09
0.08
0.05
0.05
0.07
0.03
0.03
0.02
0.02
0.03
0.03
0.01
0.01
0.02
0.054
0.065
0.069
0.078
0.059
0.064
0.071
0.054
0.05
F J�
zf
< 0.001 < 0.001
< 0.001 < 0.001
< 0.001 < 0.001
< 0.001 < 0.001
< 0.001 < 0.001
< 0.001 < 0.001
0.002 < 0.001
0.002 < 0 001
< 0.001 < 0.001
< 0.001 0.002
< 0.001 0.002
< 0.001 < 0.001
< 0.001 < 0.005
< 0.001 < 0.005
< 0.001 < 0.005
< 0.001 < 0 005
< 0.001 < 0.005
< 0.001 < 0.005
< 0.001 < 0.005
< 0.001 < 0.005
< 0.001 < 0.005
< 0.001 < 0.005
< 0.001 < 0.005
< 0.001 < 0.005
0.07
0.12
0.12
0.12
0.11
0.07
0.04
0.04
0.04
0.08
0.08
0.08
0.11
0.10
0.11
0.11
0.073
0.058
0.057
0.037
0.039
0.05
0.047
0.053
0.005
0.005
0.005
0.005
0.005
0.005
0.005
0.005
0.005
0.01
0.01
0.01
0.01
0.01
0.01
0.01
0.01
0.01
0.01
0.01
0.01
pollutant (mg/L)
UJ
2�
F
< 0 0002
< 0.0002
< 0.0002
< 0.0002
< 0.0002
< 0.0002
< 0.0002
< 0.0002
< 0.0002
< 0.0002
< 0.0002
< 0.0002
< 0.0002
< 0.0002
< 0.0002
< 0.0002
< 0.0002
< 0.0002
< 0.0002
< 0.0002
< 0.0002
< 0.0002
< 0.0002
< 0.0002
r Jam'
hQ C
CC
< 0.01
AVG.
3.790
0.0276
0.0514
0.0011
0.0031
0.0756
0.0079
0.0002
#DIV/0!
#DIV/0!
#DIV/0!
#DIV/0!
#DIV/01
0 0100
#DIV/0!
MAX.
4.507
0 0500
0.1300
0.0020
0.0050
0.1200
0.0100
0.0002
0.0000
0.0000
0.0000
0.0000
0.0000
0.0100
0.0000
MIN.
2.958
0.0050
0.0100
0.0010
0.0010
0.0370
0.0050
0 0002
0.0000
0.0000
0.0000
0.0000
0.0000
0.0100
0.0000

POTW NAME
FOREST CITY WWTP
)DES/NONDISCHARGE PERMIT #
NC 0025984
SAMPLE LOCATION
EFFLUENT
w Detection Limit Data (BDL) should be marked as "< and the detection limit" i.e. <0.
sample date flow
ollutant (ma/L
Year 2000
3/28/2000
F
4.054
0.012
0.059
< 0.001
JF
o
< 0.005
�
Q
0.11
< 0.01
/t/1Y/s/,Vs7/
< 0.0002
3/29/2000
3.579
0.014
0.15
< 0.001
< 0.005
0.11
< 0.01
< 0 0002
3/30/2000
3.589
0.015
0.075
< 0.001
< 0.005
0.13
< 0.01
< 0.0002
6/27/2000
3.908
<
0.005
0.079
< 0.001
< 0.005
0.038
< 0.01
0.0012
6/28/2000
3.950
<
0.005
0.056
< 0.001
< 0 005
0.027
< 0.01
< 0.0002
6/29/2000
3.932
<
0.005
0.062
< D.001
< 0.005
0.022
< 0 01
0.00024
9/26/2000
4.092
0.0063
0.039
< 0.001
< 0.005
0.058
< 0.01
< 0.0002
9/27/2000
4 234
<
0.005
0.07
< 0.001
< 0.005
0.051
< 0.01
< 0 0002
9/28/2000
4.153
<
0.005
0 069
< 0.001
< 0.005
0.037
< 0.01
< 0 0002
12/19/2000
4.507
0.0052
0.048
< 0.001
< 0.005
0.041
< 0.01
< 0.0002
12/20/2000
4.115
<
0.005
0.045
< 0.001
< 0.005
0.032
< 0.01
< 0 0002
12/21/2000
3.242
<
0.005
0.05
< 0.001
< 0.005
0.045
< 0 01
< 0 0002
AVG.
3 946
0.0073
0.0668
0 0010
0 0050
0.0584
0 0100
0 0003
MAX.
4.507
0 0150
0 1500
0.0010
0.0050
0.1300
0 0100
0.0012
MIN.
3.242
0.0050
0.0390
0.0010
0 0050
0.0220
0 0100
0.0002

POTW NAME
FOREST CITY WWTP
'DES/NONDISCHARGE PERMIT #
NC 0025984
SAMPLE LOCATION
EFFLUENT
Below Detection Limit Data (BDL) should be marked as "< and the detection limit" i.e. <0.002.
sample date flow
ollutant (ma/L
Year 2001
3/27/2001
3/28/2001
3/29/2001
Z/1/ti/i/S/,/j
4.888
4.493
7.067
< 0.0050
< 0.0050
0.0058
0.047
0.045
0.045
< 0.0010
< 0.0010
< 0 0010
< 0,0050
< 0 0050
< 0.0050
0.041
0.035
0 059
< 0.010
< 0.010
< 0 010
F°
< 0.00020
< 0.00020
< 0 00020
Q.
��
°
c
,.
�
2nd quarter samples missed for 2001
8/14/2001
3.983
< 0.0050
0.044
< 0.0010
< 0.0050
0.042
< 0.010
< 0.00020
8/15/2001
3.902
< 0.0050
0.042
< 0.0010
< 0.0050
0.039
< 0.010
< 0 00020
8/16/2001
3.833
< 0.0050
0.037
< 0.0010
< 0.0050
0 053
< 0 010
< 0.00020
11/27/2001
4.080
< 0.0052
0.037
< 0.0010
< 0.0050
0.028
< 0.010
< 0.00020
11/28/2001
4.035
< 0 0050
0.033
< 0.0010
< 0 0050
0 022
< 0 010
< 0.00020
11/29/2001
3.836
< 0 0050
0.023
< 0.0010
< 0 0050
0 019
< 0 010
< 0.00020
AVG.
4 457
0.0051
0.0392
0.0010
0.0050
0 0376
0 0100
0.0002
MAX.
7.067
0.0058
0.0470
0.0010
0.0050
0 0590
0 0100
0 0002
MIN.
3 833
0.0050
0.0230
0 0010
0 0050
0 0190
0 0100
0.0002

POTW NAME
FOREST CITY WWTP
'DES/NONDISCHARGE PERMIT #
NC 0025984
SAMPLE LOCATION
EFFLUENT
Below Detection Limit Data (BDL) should be marked as "< and the detection limit" i.e. <0.002.
sample date flow
pollutant (mg/L)
Year 2002
1st quarter samples missed for 2002
Start monthly Long Term Monitoring
July 2002
4/3/2002
3.888
< 0.0050
0.038
< 0.0010
< 0 0050
0.021
< 0.010
< 0.00020
4/4/2002
3.993
< 0.0050
0.034
< 0.0010
< 0 0050
0.018
< 0.010
< 0.00020
4/5/2002
4 095
< 0.0050
0.033
< 0.0010
< 0 0050
0 023
< 0 010
< 0 00020
7/23/2002
3.859
< 0.0050
0.036
< 0.0010
< 0 0050
0.058
< 0.010
< 0.00020
7/24/2002
3.820
< 0.0050
0.049
< 0.0010
< 0.0050
0.057
< 0 010
< 0 00020
7/25/2002
3.633
< 0.0050
0.029
< 0.0010
< 0 0050
0 061
< 0 010
< 0.00020
8/20/2002
3.814
< 0.0050
0.054
< 0.0010
< 0 0050
0 025
< 0.010
< 0.00020
8/21/2002
3.705
< 0.0050
0.054
< 0.0010
< 0 0050
0 035
< 0 010
< 0 00020
8/22/2002
3.700
< 0.0050
0 044
< 0 0010
< 0 0050
0 035
< 0 010
< 0.00020
9/24/2002
3.259
< 0.0050
0.044
< 0.0010
< 0 0050
0 049
< 0 010
< 0.00020
9/25/2003
3.736
0.0063
0.049
< 0.0010
< 0.0050
0.062
< 0 010
< 0.00020
9/26/2003
4.812
< 0.0050
0 041
< 0 0010
< 0 0050
0 054
< 0 010
< 0.00020
10/29/2002
3.628
0.0061
0.040
< 0.0010
< 0.0050
0 038
< 0 010
< 0.00020
10/30/2002
3.609
< 0.0050
0 057
< 0.0010
< 0 0050
0 035
< 0.010
< 0.00020
10/31/2002
3.528
< 0.0050
0.046
< 0.0010
< 0 0050
0 034
< 0 010
< 0.00020
11/19/2002
3.567
< 0.0050
0.045
< 0.0010
< 0.0050
0 033
< 0.010
< 0.00020
11/20/2002
3.460
< 0.0050
0.05
< 0.0010
< 0.0050
0.041
< 0.010
< 0.00020
11/21/2002
3.244
< 0.0050
0 053
< 0 0010
< 0.0050
0 040
< 0.010
< 0.00020
12/18/2002
3.644
< 0.0050
0.046
< 0.0010
< 0.0050
D 039
< 0,010
< 0.00020
12/19/2002
4.412
< 0.0050
0.04
< 0.0010
< 0.0050
0.035
< 0.010
< 0.00020
12/20/2002
4.570
< 0 0050
0 038
< 0.0010
< 0.0050
0.043
< 0.010
< 0 00020
AVG.
3 808
0.0051
0.0438
0 0010
0.0050
0 0398
0 0100
0.0002
MAX.
4 812
0 0063
0.0570
0.0010
0.0050
0.0620
0.0100
0 0002
MIN.
3.244
0.0050
0.0290
0.0010
0.0050
0 0180
0 0100
0.0002
1

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(Jul)alzu a!dwES

State of North Carolina
Department of Environment
and Natural Resources
Division of Water Quality
Michael F. Easley, Governor
William G. Ross, Jr., Secretary
Alan W. Klimek, P.E., Director
MEMORANDUM
To:
September 9, 2003
Harold Saylor
NC DENR / DEH / Regional Engineer
Asheville Regional Office
From: Charles H. Weaver, Jr.
NPDES Unit
Subject:
Ow
Review of Draft NPDES Permit NC0025984
Town of Forest City WWTP
Rutherford County
A7A
NCDENR
NORTH CAROLINA DEPARTMENT OF
ENVIRONMENT AND NATURAL RESOURCES
9/u/o3
,'jc
o Arc
A/• •:.SC.0 Oft
/ ; nr
03
Please indicate below your agency's position or viewpoint on the draft permit and return this form by October 10,
2003. If you have any questions on the draft permit, please contact me at the telephone number or e-mail address
listed at the bottom of this page.
ti1.4, '— .7t OCR►++,4k, �?
RESPONSE: (Check one)
Signed
OIL
•
g **—►.1'...-i
Concur with the issuance of this permit provided the facility is operated and maintained properly, the stated effluent limits
are met prior to discharge, and the discharge does not contravene the designated water quality standards.
Concurs with issuance of the above permit, provided the following conditions are met:
Opposes the issuance of the above permit, based on reasons stated below, or attached:
�1CI&4', "CPC Pfe, 0 Date: 0
545_
1617 Mail Service Center, Raleigh, North Carolina 27699-1617 919 733-5083, extension 511 (fax) 919 733-0719
VAsir us ON THE INTERNET @ http://h2o.enr.state.nc.us/NPDES Chartes.Weaver@ ncmail.net

DENR/DWQ
FACT SHEET FOR NPDES PERMIT DEVELOPMENT
NPDES Permit NC0025984
Facility Information
Applicant/Facility Name:
Town of Forest City/ Forest City Wastewater Treatment Plant
Applicant Address:
P.O. Box 728, Forest City, North Carolina 28043
Facility Address:
397 Riverside Drive; Forest City, North Carolina 28043
Permitted Flow
4.95 MGD
Type of Waste:
Domestic (12%) and industrial (88%) with full pretreatment program
Facility/Permit Status:
Class IV /Active; Renewal
County:
Rutherford County
Miscellaneous
Receiving Stream:
Second I3road
River
Regional Office:
Asheville (ARO)
Stream Classification:
WS-IV
USGS Quad:
Forest City, N.C.
303(d) Listed?
No
Permit Writer:
Natalie V. Sierra
Subbasin:
Drainage Area (mi2):
Summer 7Q10 (cfs)
03-08-02
168
34.8
Date:
August 28, 2003
Winter 7Q10 (cfs):
70.6
30Q2 (cfs)
112
Average Flow (cfs):
247
IWC (%):
18%
Lat. 35° 19' 38" N Long. 81° 50' 25" W
BACKGROUND
The Forest City Wastewater Treatment Plant is a 4.95 MGD treatment facility serving the residents of
Forest City and seven Significant Industrial Users. The Town has a full pretreatment program with the
Division of Water Quality's Pretreatment Unit and will continue to implement this program in the
coming permit term. Sludge is treated to Class A standards and made available to local farmers and
residents.
The Permittee applied for renewal by submitting EPA Form 2A on February 13, 2003. The previous
permit was issued on October 26, 1998 and expired on July 31, 2003.
Instream Monitoring and Verification of Existing Conditions and DMR Data Review.
This facility discharges to sub -basin 03-08-02 in the Second Broad River, which is in the Broad River
Basin. The Second Broad River is not listed as impaired (303(d) listed as of the 2002). The Permittee is
required to monitor for dissolved oxygen, fecal coliform, temperature and conductivity. Data plots,
based on Discharge Monitoring Report (DMR) data from January 2001 through May 2003, of these
parameters are attached to this fact sheet. Downstream temperature and fecal coliform were generally
slightly above the upstream values. Downstream dissolved oxygen was slightly less than the upstream
values, but never below 6.0 mg/L. Only instream conductivity demonstrated a difference between
upstream and downstream -- downstream conductivity was often twice the upstream value.
In addition to instream monitoring, Forest City is also required to monitor effluent flow, BOD, Total
Suspended Solids (TSS), dissolved oxygen, fecal coliform, total residual chlorine (TRC), phenols,
ammonia nitrogen (NH3-N), total nitrogen, total phosphorus, and temperature. Toxicant monitoring
(except phenols and TRC) is discussed in the Reasonable Potential Analysis section. Effluent data for
conventional parameters is summarized in Table 1. The maximum value for TSS reveals an excursion —
there were two violations of the monthly average limit in March and May 2003. Toxicants and nutrients
are summarized in Table 2.
Fact Sheet
NPDES NC0025984 Renewal
Page 1

Avera e
Maximum
Minimum
Flow Temp. (Deg C) D.O. (mg/L) BOD (mg/L) TSS (mg/L)
(MGD)
3.80
4.67
3.02
22.01
29.74
14.63
7.06
7.7
6.36
8.66
21.42
3.61
13.59
45.24
7.23
Fecal
coliform
(#/100 mL)
1.7
3.56
1
Table 1 NC0025984 -
DMR data for conventional parameters (January 2001-May 2003)
Avera e
Maximum
Minimum
Phenols
(mg/L)
0.01
0.09
0
TRC (µg/L) NH3-N (mg/L) Total
Nitrogen
(mg/L)
0.12
2.25
0
0.8
1.85
0
9.5
13
7.5
Total
Phosphorus
(mg/L)
3.5
5.6
1.7
Table 2 NC0025984 -
DMR data for toxicants and nutrients (January 2001 - May 2003)
Correspondence
The Asheville Regional Office (ARO) conducted a number of compliance evaluation inspections
throughout the permit term and prepared a Staff Report in conjunction with this renewal. The inspection
reports all state that the facility is in compliance and well operated. The staff report recommends
renewal of the permit.
The Town of Forest City has received four Notices of Violation (NOVs) during this permit term. Two of
these had civil penalties associated with them. Of the four, three were associated with violations of the
TSS limits. In addition to TSS limits violations, one of the NOVs was also related to violations of the
dissolved oxygen limit and the weekly average BOD limit. The fourth NOV was for overflow due to
inflow and infiltration.
PERMITTING STRATEGY
Waste Load Allocation (WLA)
The Division prepared the last WLA in conjunction with the previous permit renewal. The previous and
current effluent limits were based on guidelines and water quality standards. The Division has judged
previous parameters and limits to be appropriate for renewal with some exceptions (see Reasonable
Potential Analysis). A weekly average ammonia limit based on a 3:1 ratio with the monthly average will
be implemented in this permit. This is a new statewide policy that resulted from EPA requirements and
results in a weekly average limit of 30.0 mg/L.
In addition, an annual pollutant scan will be added such that the Permittee can collect the necessary data
required by EPA Form 2A throughout the permit term. This condition is now standard on all major
municipal permits in North Carolina.
Reasonable Potential Analysis (RPA)
The Division conducted EPA -recommended analyses to determine the reasonable potential for toxicants
to be discharged by this facility, based on DMR data from January 2001 through May 2003. Calculations
included parameters listed in the previous permit and pre-treatment documents to include: cadmium,
chromium, copper, cyanide, lead, mercury, nickel, silver and zinc.
Results suggest no reasonable potential for the facility to discharge cadmium, chromium, nickel and
zinc. None of these are currently monitored through the NPDES permit. Reasonable potential was
indicated for copper, cyanide, mercury, lead, and silver. As a result, cyanide limits will be added to the
permit and monitoring will be increased to weekly. Lead, not currently monitored in the NPDES permit,
will be added with limits and weekly monitoring. Mercury is already limited and monitored in the
existing permit. Likewise, copper and silver are monitored twice monthly in the existing permit but are
not limited because they are action level parameters.
LMO 41Goonebh e04-41e-1 PAkeue
D(024 Cht—cild _ tid,,:s7
Fact Sheet
NPDES NC0025984 Renewal
Page 2

Priority Pollutant Analysis
The Permittee submitted a priority pollutant analysis in conjunction with the permit renewal. Copper,
zinc, cyanide and phenols were all detected in this analysis (note: although the Permittee reported on
Form 2A that chloroform and bis(2-ethylhexyl)phthalate were detected, the report from the lab
contradicts this and lists the samples as non -detects). These parameters are all monitored through the
permit or pretreatment program.
SUMMARY OF PROPOSED CHANGES
In keeping with Division policies, the following will be incorporated into the permit:
• A weekly average ammonia limit of 30.0 mg/L
• Annual pollutant scan
• Added lead monitoring and limit
• Added cyanide limits and increased monitoring (from 2/month to weekly)
New Weekly Average and Daily Maximum limits are derived from the latest NC/EPA policies considering '/
FA Vs and allowable concentrations based on reasonable potential.
Attachments: DMR data summary, instream data plots, RPA summary
PROPOSED SCHEDULE FOR PERMIT ISSUANCE
Draft Permit to Public Notice:
Permit Scheduled to Issue:
September 10, 2003
November 3, 2003.
NPDES DIVISION CONTACT
If you have questions regarding any of the above information or on the attached permit, please contact
Natalie Sierra at (919) 225-0 76.
NAME:
REGIONAL OFFICE COMMENTS
DATE: Cr CeP ZJ
NAME: DATE:
SUPERVISOR: DATE:
Fact Sheet
NPDES NC0025984 Renewal
Page 3

Facility Name =
Qw (MGD) _
WWTP Classification
NPDES # =
Receiving Stream
IWC (%) =
Town of Forest City
4.95
4
NC0025984
Second Broad River
18.06
Reasonable Potential Summary
Stream Classification
7Q10s (cfs)=
30Q2 (cfs)
Qavg (cfs)
1° 2°
30
4°
WS-IV
34.8
112
247
Final Results:
Cadmium
Max. Pred Cw
Allowable Cw
0.5 µg/1
11.1 µg/1
'Implementation
:Are all reported values less than?
,Is the detection limit acceptable?
Yes
Yes
Limit?
Monitor?
No
No
;Monitoring
,Frequency None
I
1/2 FAV (non Trout)
15.0Iµg/1
1
Chromium
Max. Pred Cw
Allowable Cw
3.1 µg/l
276.8 µg/l
'Implementation
'Are all reported values less than?
;Is the detection limit acceptable?
Yes
Yes
Limit?
Monitor?
No
No
' Monitoring
!Frequency None
1/2 FAV
10221141
Copper
Max. Pred Cw
Allowable Cw
137.7 µg/1
38.7 µg/I
'Implementation
'Are all reported values less than?
!1s the detection limit acceptable?
No
Yes
Limit?
Monitor?
No
Yes
'Monitoring
� Frequency 2/Month
1
1/2 FAV
7.3 µg/l
I
Cyanide
Max. Pred Cw
Allowable Cw
3659.7 µg/1
27.7 µg/I
:Implementation
,Are all reported values less than?
'Is the detection limit acceptable?
No
Yes
Limit?
Monitor?
Yes
Yes
i
, Monitoring
I Frequency Weekly
1/2 FAVI
22.0 µg/1
1
1, c: u I
Max. Pred Cw
Allowable Cw
669.2 µg/1
138.4 µg/1
'Implementation
!Are all reported values less than?
ils the detection limit acceptable?
No
Yes
Limit?
Monitor?
Yes
Yes
'
, Monitoring
I Frequency Weekly
#
1/2 Favl
33.81µg/1
1
Mercury
Max. Pred Cw
Allowable Cw
1.6083 µg/1
0.0664 µg/1
;Implementation
!Are all reported values less than?
Its the detection limit acceptable?
No
Yes
Limit?
Monitor?
Yes
Yes
1
! Monitoring
I Frequency Weekly
Nickel
Max. Pred Cw
Allowable Cw
9.1 µg/l
138.4 µg/I
:Implementation
,Are all reported values less than?
Its the detection limit acceptable?
No
Yes
Limit?
Monitor?
No
No
' Monitoring
I Frequency None
1/2 FAVI
261.01µg/I
1
Silver
Max. Pred Cw
Allowable Cw
3.6 µg/l
0.3 µg/I
'Implementation
!Are all reported values less than?
Its the detection limit acceptable?
NO
Yes
Limit?
Monitor''
No
Yes
'
!Monitoring
I Frequency 2/Month
l/2 FAVI
1.2114/1
Zinc
Max. Pred Cw
Allowable Cw
81.6 µg/I
276.8 g/1
, Implementation
!Are all reported values less than?
lis the detection limit acceptable?
No
Yes
Limit?
Monitor?
No
No
!Monitoring
I Frequency None
'
1/2 FAVI
67.01µg/I
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Forest City - NC0025984
DMR Data Summary
Date
Temp. (deg Fecal (#7100 Phenols NH3-N
Flow (MGD) C) D.O. (mg/L) BOD (mg/L) TSS (mg/L) mL) (mg/L) TRC (ug/L) (mg/L) TN (mg/L) TP (mg/L)
Jan-01 4.2641 15.36 7.66 6.64 9.6 2.3 0.0168 0 0.5
Feb-01 4.3315 18.61 7.26 9.67 9.3 1.5 0.0138 0 0.81 8.1 5.6
Mar-0I 4.6709 18.7 7.43 5.9 11.3 1.3 0.0115 0 0.72
Apr-01 4.0723 23.18 6.73 10.57 13.4 1.1 0.0065 0 1.01 8.2 4
May-01 3.646 24.09 6.51 8.77 12.3 1.1 0.006 0 0.92
Jun-01 4.3501 27.38 6.43 8.19 11.5 1.3 0.0105 0 0.34
Jul-01 3.2764 26.62 6.7 8.09 8 3.1 0.0057 1.095 1.07 7.7 3.2
Aug-01 3.8281 28.93 6.54 7 10.6 1.2 0.0105 0 0.9
Sep-01 3.9849 25.84 6.84 6.87 12.7 1.9 0.003 0 0.43
Oct-01 3.773677 22.56 6.75 6.65 11.6 1.4 0.008 0 1.08 10 ;
Nov-01 3.927067 20.51 7.22 7.99 11.05 1 0 1.03
Dec-01 3.215065 18.16 7.03 9.63 9.84 2.1 0.0083 0 1.51
Jan-02 3.855742 17.05 7.44 8.32 12.95 1.198 0.011 0 1.85 7.5 I -
Feb-02 3.830393 17.21 7.295 7.18 10.1 1.55 0 1.08
Mar-02 3.820903 19.2 7.67 7.8 12 2.17 0 0.41
Apr-02 3.727567 23.91 7.17 7.35 7.9 1 0 0 0.53 7.0
May-02 3.561581 24.87 6.47 6.31 7.23 1 0 0.49
Jun-02 3.554667 28.53 6.56 7.92 7.85 1.06 0 1.08
Jui-02 3.258677 29.74 6.36 9.98 8.5 1.12 0 1.51
Aug-02 3.61971 27.99 6.83 3.61 8.64 3.35 0.09 0 0
Sep-02 3.5435 26.57 6.82 4.62 11.9 2.11 0 0 0 13 I
Oct-02 3.355484 23.36 7.13 6.35 17.17 1.44 0 0.56 II 4
Nov-02 3.607667 19.17 7.62 6.34 11.35 2.85 0 0.74
Dec-02 3.730065 15.12 7.7 10.53 24.7 1.89 0.0074 2.25 0.86
Jan-03 3.02 14.63 7.66 7.79 9.27 1.16 0.0027 0 1.07 9.0
Feb-03 3.1 16.64 7.46 8.32 8.4 1.27 0 1.03
Mar-03 4.05 20.16 7.46 21.42 45.24 3.56 0 1.26
Apr-03 4.57 20.81 7.14 18.7 26.14 1.56 0.00665 0 1.18 12 c,
May-03 4.65 23.53 6.8 12.58 33.71 2.82 0 0.53
Average 3.80 22.01 7.06 8.66 13.59 1.7 0.01 0.12 0.8 9.5 3.5
Maximum 4.6709 29.74 7.7 21.42 45.24 3.56 0.09 2.25 1.85 13 5.6
Minimum 3.02 14.63 6.36 3.61 7.23 1 0 0 0 7.5 1.7

1800
1600
NC0025984 - Instream Fecal Coliform
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Oct-00 Jan-01 Apr-01 Jul-01 Nov-01 Feb-02 May-02 Sep-02 Dec-02 Mar-03 Jun-03
Date
• Upstream
■ Downstream

Dissolved Oxygen (mg/L)
NC0025984 - Instream Dissolved Oxygen
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Oct-00 Jan-01 Apr-01 Jul-01 Nov-01 Feb-02 May-02 Sep-02 Dec-02 Mar-03 Jun-03
Date
♦ Upstream
® Downstream

Conductivity (umhos)
1400
1200
1000
800
600
400
200
0
Oct-00 Jan-01 Apr-01 Jul-01 Nov-01 Feb-02 May-02 Sep-02 Dec-02 Mar-03 Jun-03
Date
NC0025984 - Instream Conductivity
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NC0025984 - Instream Temperature
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4
SOC PRIORITY PROJECT:
IF YES, SOC NUMBER
TO: PERMITS AND ENGINEERING UNIT
WATER QUALITY SECTION
ATTENTION: Charles Weaver
DATE: April 14, 2003
No
NPDES STAFF REPORT AND RECOMMENDATION
Rutherford COUNTY
PERMIT NUMBER NC0025984
PART I - GENERAL INFORMATION
1.
Facility and Address:
Mailing:
APR 1 4 2003
Town of Forest City WWTP,
397 Riverside Drive
Post Office Box 728
Forest City, North Carolina 28043
2. Date of Investigation: January 29, 2003
3. Report Prepared By: Roger C. Edwards
4. Persons Contacted and Telephone Number: Jeff Dotson, ORC
828-248-5217
5. Directions to Site: From Hwy.74 By -Pass take the Old Caroleen Road
exit. At the end of the exit ramp turn left onto Old Caroleen Road,
travel approx. 2.5 miles to Riverside Drive. Turn right onto
Riverside Drive and travel approx. 1 mile to the WWTP.
6. Discharge Point(s), List for all discharge points:
Latitude: 35 38" Longitude: 81- `3O' 23"
Attach a USGS map extract and indicate treatment facility site and
discharge point on map.
U.S.G.S. Quad No. U.S.G.S. Quad Name Forest City, NC
7. Site size and expansion area consistent with application?
No If No, explain:
X Yes
Page 1

8. Topography (relationship to flood plain included): 5 to 10 % slope
adjacent to flood plain.
9. Location of nearest dwelling: 2000 feet
10. Receiving stream or affected surface waters:
a. Classification: WS III
b. River Basin and Subbasin No.: BRD 030802
c. Describe receiving stream features and pertinent downstream
uses: Source of process and potable water, wildlife habitat,
and agriculture.
PART II - DESCRIPTION OF DISCHARGE AND TREATMENT WORKS
1. a. Volume of wastewater to be permitted 4.95 MGD (Ultimate
Design Capacity)
b. What is the current permitted capacity of the Wastewater
Treatment facility? 4.95 MGD
c. Actual treatment capacity of the current facility (current
design capacity 4.95 MGD
d. Date(s) and construction activities allowed by previous
Authorizations to Construct issued in the previous two years:
N/A
e. Please provide a description of existing or substantially
constructed wastewater treatment facilities: Influent bar screen,
grit and grease removal, primary and secondary aeration,
secondary clarification, chlorination and dechlorination. Sludge
disposal is thicken, digest, belt press, to dryer. Final
disposal is land application by public of a class "A" product.
f. Please provide a description of proposed wastewater treatment
facilities: N/A
g•
Possible toxic impacts to surface waters: Influent to the WWTP
is 70% industrial and 30% domestic. There is a possibility of
toxins present in the effluent however, the effluent is tested
quarterly not indicating any problem.
h. Pretreatment Program (POTWs only):
in development approved X
should be required not needed
Page 2

2. Residuals handling and utilization/disposal scheme: Class "A"
product, can be applied by public
a. If residuals are being land applied, please specify DWQ Permit
Number WQ0010926
Residuals Contractor
Telephone Number
b. Residuals stabilization: PSRP PFRP X OTHER
C. Landfill:
d. Other disposal/utilization scheme (Specify):
3. Treatment plant classification (attach completed rating sheet):
4. SIC Codes(s): 4952
Primary Secondary
Main Treatment Unit Code: 050-3
PART III - OTHER PERTINENT INFORMATION
1. Is this facility being constructed with Construction Grant Funds or
are any public monies involved. (municipals only)? N/A this is a
permit renewal for as existing facility.
2. Special monitoring or limitations (including toxicity) requests: N/A
3. Important SOC, JOC, or Compliance Schedule dates: (Please indicate)
N % T:
Submission of Plans and Specifications
Begin Construction
Complete Construction
Date
4. Alternative Analysis Evaluation: Has the facility evaluated all of
the non -discharge options available. Please provide regional
perspective for each option evaluated. N/A

Spray Irrigation:
Connection to Regional Sewer System:
Subsurface:
Other disposal options:
5. Other Special Items: N/A
PART IV - EVALUATION AND RECOMMENDATIONS
The NPDES Permit should be renewed for discharge of 4.95 MGD.
Signature of Report Preparer
..f
ater Quality Regional Supervisor
Page 4

O�T.&-9
OG ATA
7r NCDENR
Mr. Charles Summey — Town Manager
Town of Forest City
PO Box 728
Forest City, North Carolina 28043
Dear Mr. Summey:
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
February 28, 2003
Subject: NPDES Permit renewal application
Permit NC0025894
Forest City WWTP
Rutherford County
NPDES Unit personnel received your permit renewal application on February 13, 2003. Thank you for
submitting this package. We need some additional items in order to process your permit renewal:
• 1 Copies of your application
The permit renewal for this facility will be assigned to a staff member. This staff member will
contact you if further information is needed to complete the permit renewal. Please note that the NPDES
Unit has several vacant positions. This staff shortage has lasted for over 4 years and is delaying all permit
renewals. Our remaining permit writers are currently reviewing Authorizations to Construct, speculative
limit requests, major permit modifications and 201 plan updates ahead of permit renewals.
If this staff shortage delays reissuance of your permit, the existing requirements will remain in
effect until the permit is renewed (or the Division takes other action). We appreciate your patience and
understanding while we operate with a depleted staff. If you have any additional questions concerning
renewal of the subject permit, please contact Charles Weaver at [phone], extension 511.
cc: Asheville Regional Office/Water Quality Section
NPDES Unit
Central Files
N. C. Division of Water Quality / NPDES Unit
1617 Mail Service Center, Raleigh, NC 27699-1617
Internet: h2o.enr.state.nc.us
Sincerely,
OALLA-1
Valery Stephens
Point Source Branch
Phone: [phone], extension 520 Fax: [phone]
DENR Customer Service Center: 1 800 623-7748
e-mail: valery [e-mail]

`0'j! ` pr,
jfrl\ 7
Mr. Charles R. Summey
Town of Forest City
PO Box 728
Forest City, North Carolina 28043
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
February 13, 2003
Subject: COPPER AND ZINC ACTION LEVEL POLICY
Effluent Toxicity Testing
NPDES Permit No. NC0025984
Town of Forest City WWTP
Rutherford County
Dear Mr. Summey:
F E B 1 9 2003
This letter is to notify you that our office did not receive a Final Report from the Town
detailing actions to rule out copper as a causative effluent toxicant. A final report was due on or before
January 26, 2003.
In a Notice of Violation (NOV) dated 4/8/02 from the Asheville Regional Office, the Town
received notification that the WWTP had reasonable potential to violate the instream action level Total
for copper. In a subsequent NOV dated 4/26/02 the Town was formally notified that it would be given
nine months to provide DWQ with evidence to definitively rule out copper as a causative effluent
toxicant. By letter dated 5/21/02 the Town notified DWQ of its decision to conduct a Toxicity
Identification Evaluation (Option 3).
A review of the facility's toxicity self -monitoring data from March 2002 through January 2003
indicates that no additional effluent toxicity permit limit violations occurred.
While our office is disappointed that the Town did not submit a final report, we choose, at this
time, not to reopen your NPDES Permit to include a permit limitation for copper. Please be advised
that the Town of Forest City remains subject to the provisions of DWQ's Copper and Zinc Action
Level Policy should additional effluent toxicity violations occur in the future (ie, two effluent toxicity
permit limit violations occurring within the toxicity testing calendar quarter defined by the NPDES
Permit).
The Town may consider "spiking" effluent samples which are not toxic with known
concentrations of copper to determine a threshold concentration at which copper would impact aquatic
life in the receiving stream. If the facility chooses to "spike" effluent samples with copper, then at
least three separate trials must be conducted.
S P\
NCDENR
Customer Service
800 623-7748
Environmental Sciences Branch 1621 Mail Service Center Raleigh, NC 27699-1621 [phone]

•
Page 2
Town of Forest City -Copper and Zinc Action Level Policy
February 13, 2003
If you have any questions concerning this correspondence, please contact me or Mr. Kevin
Bowden with the Aquatic Toxicology Unit at [phone].
Sincerely,
Matt Matthews, Supervisor
Aquatic Toxicology Unit
cc: Forrest Westall-Asheville Regional Office
Dave Goodrich-NPDES Unit
Susan Wilson-NPDES Unit
Kevin Bowden -Aquatic Toxicology Unit
Pretreatment Unit
Madolyn Dominy, USEPA Region IV, Water Mgt. Div., Atlanta Federal Center, 61
Forsyth St., SW, Atlanta GA 30303
Shannon Langley -Point Source Compliance/Enforcement Unit
Central Files

State of North Carolina
Department of Environment and Natural Resources
Division of Water Quality
59 Woodfin Place Asheville, North Carolina 28801
CERTW1bD MAIL
RETURN RECEIPT REOUESTED
Mr. Charles R. Summey
Town of Forest City
PO Box 728
Forest City, North Carolina 28043
SUBJECT:
Dear Mr. Summey:
April 26, 2002
NOTICE OF VIOLATION
Whole Effluent Toxicity (WET) Testing
Copper and Zinc Action Level Policy
NPDES Permit No. NC0025984
Town of Forest City WWTP
Rutherford County
This is to inform you that a review of your toxicity self -monitoring report form for the month of
February 2002 indicates a violation of the toxicity limitation specified in your NPDES Permit. You
should undertake necessary actions to eliminate or reduce effluent toxicity to acceptable levels.
Previous correspondence was sent to you concerning implementation of the Division's Copper
and Zinc Action Level Policy. The correspondence included prospective permit limits for copper and/or
zinc and stated that the trigger for implementing the policy would be two or more WET limit violations
which occur during a toxicity testing calendar quarter. Please note that the second WET limit violation
has occurred and you must provide:
a) Written notification indicating acceptance of the prospective copper and/or
zinc permit limit. Notification is due by May 26, 2002.
OR
b) Written notification indicating your choice of option(s) 1-4 below. Notification is due by
May 26, 2002. DWQ approval of options 1-3 (below) is not necessary as the Division
expects work to rule out copper and/or zinc as causative effluent toxicants to begin
immediately upon the second WET permit limit violation.
1. Instream measurements of dissolved metal during low flow conditions that demonstrate
compliance with the Action Level standard
2. A revision of the prospective permit limit using improved inputs that in concert with
existing or additional monitoring data demonstrates compliance with the Action Level
standard
3. Toxicity Identification Evaluation (TIE) results that definitively rule out copper and/or
zinc as causes of effluent toxicity
4. Demonstration by an alternative method approved by the Division and EPA that copper
and/or zinc is not the cause of toxicity

2
Written notification (a or b above) shall be sent to:
North Carolina Division of Water Quality
Environmental Sciences Branch
Aquatic Toxicology Unit
1621 Mail Service Center
Raleigh, North Carolina 27699-1621
Q r
SAY - 3 2002
Please note that if you choose item b) above, you will be given nine months to submit
documentation that eliminates copper and/or zinc as causative effluent toxicants. Your final report
should be comprehensive and include all data used to support your conclusion. The report is due on or
before January 26, 2003.
Three copies of the final report shall be submitted to:
North Carolina Division of Water Quality
Environmental Sciences Branch
Aquatic Toxicology Unit
1621 Mail Service Center
Raleigh, North Carolina 27699-1621
Failure to notify DWQ of your acceptance of a copper and/or zinc limit, failure to notify DWQ
of your option selection or failure to make acceptable demonstration to DWQ that copper and/or zinc are
not causative effluent toxicants within the stated time frames will result in reopening of the NPDES
Permit to include copper and/or zinc numeric limitations, as appropriate.
If the effluent is toxic, then we expect work to commence immediately with toxic effluent
samples. Failure to initiate work with toxic effluent samples during the study period is unacceptable and
will be considered a failure to make acceptable demonstration as cited above. We recommend a
minimum of three separate sampling events during the nine month period to definitively rule out copper
and/or zinc as causative effluent toxicants.
Additional information regarding the Division's copper and/or zinc action level policy can be
found at the following web site - http://www.esb.enr.state.nc.us/. Click on the Aquatic Toxicology
Unit and go to the prompt "DOWNLOADS" located at the bottom of the page.
If you have any questions concerning this correspondence, please contact me at [phone]
or Mr. Matt Matthews, Supervisor of the Aquatic Toxicology Unit at [phone].
Sincerely,
Forrest Westall
Regional Water Quality Supervisor
cc: Asheville Regional Office
Susan Wilson-NPDES Unit
Tom Poe -Pretreatment
Lydia Mayo-USEPA Region IV, Atlanta Federal Center, 61 Forsyth St., SW, Atlanta, GA 30303
Central Files
Aquatic Toxicology Unit Files

State of North Carolina
Department of Environment and Natural Resources
Division of Water Quality
59 Woodfin Place Asheville, North Carolina 28801
CERTIFIED MAIL
RETURN RECEIPT REQUESTED
Mr. Charles R. Summey
Town of Forest City
P.O. Box 728
Forest City, North Carolina 28043
SUBJECT:
Dear Mr. Summey:
April 8, 2002
NOTICE OF VIOLATION
Whole Effluent Toxicity (WET) Testing
Copper and Zinc Action Level Policy
NPDES Permit No. NC0025984
Town of Forest City WWTP
Rutherford County
APR 1 0 2002
DEAR - WATER QUALITY
POINT SOURCE BRANCH
This is to inform you that a review of your toxicity self -monitoring report form for the month of
January 2002 indicates a violation of the toxicity limitation specified in your NPDES Permit. You should
undertake necessary actions to eliminate or reduce effluent toxicity to acceptable levels.
The Division's Copper and Zinc Action Level Policy is triggered by two or more toxicity limit
violations that occur during the toxicity testing calendar quarter specified by the toxicity testing special
condition of your NPDES Permit. You have previously received attachments addressing policy
implementation and a copy of the Division's Toxicity Reduction Guidance.
You should initiate follow-up toxicity testing upon a single WET test failure which occurs
during the toxicity testing calendar quarter.
Your facility is currently monitoring for copper and/or zinc and is exceeding the action level for
these parameters. The policy states that whenever a facility experiences two or more toxicity limit
violations during a toxicity testing calendar quarter, the NPDES Permit will be modified to include
numeric limits for copper and/or zinc UNLESS the permittee provides one or more of the following:
1. Instream measurements of dissolved metal during low flow conditions that demonstrate
compliance with the Action Level standard
2. A revision of the prospective permit limit using improved inputs that in concert with existing
or additional monitoring data demonstrates compliance with the Action Level standard
3 Toxicity Identification Evaluation (TIE) results that definitively rule out copper and/or zinc
as causes of effluent toxicity
4. Demonstration by an alternative method approved by the Division and EPA that copper
and/or zinc is not the cause of toxicity
The Division has evaluated your copper and/or zinc monitoring data. The Division has also
developed a prospective NPDES permit limit based on your facility's instream waste concentration, the

2
copper and/or zinc action level criterion and a translator procedure. Based on this data your prospective
copper permit limit is 99 µg/L.
The permittee, upon experiencing two or more toxicity limit violations during a toxicity
testing calendar quarter must either provide DWQ with:
a) Written notification indicating acceptance of the prospective copper
and/or zinc permit limit. Notification is due within 30 days after the date of
the second WET Notice of Violation.
OR
b) Written notification indicating your choice of option(s) as noted on page
one of this correspondence. Notification is due within 30 days after the date
of the second WET Notice of Violation. DWQ approval of options 1-3
(previous page) is not necessary as the Division expects work to rule out
copper and/or zinc as causative effluent toxicants to begin immediately upon
the second WET permit limit violation
Written notification (a or b above) shall be sent to:
North Carolina Division of Water Quality
Environmental Sciences Branch
Aquatic Toxicology Unit
1621 Mail Service Center
Raleigh, North Carolina 27699-1621
Please note that if you choose item b) above, you will be given nine months to submit
documentation that eliminates copper and/or zinc as causative effluent toxicants. Your final report
should be comprehensive and include all data used to support your conclusion(s). Should the data
indicate copper and/or zinc as the source of effluent toxicity or if the data are inconclusive as to copper
and/or zinc's role as a toxicity source, then the NPDES Permit will be reopened and the metal Iimits
specified above will be applied to the permit. The report is due nine months after the date of the second
WET Notice of Violation.
Three copies of the final report shall be submitted to:
North Carolina Division of Water Quality
Environmental Sciences Branch
Aquatic Toxicology Unit
1621 Mail Service Center
Raleigh, North Carolina 27699-1621
You should consider submitting the above correspondence certified mail.
Failure to notify DWQ of your acceptance of a copper and/or zinc limit, failure to notify
DWQ of your option selection or failure to make acceptable demonstration to DWQ that copper
and/or zinc are not causative effluent toxicants within the stated time frames will result in
reopening of the NPDES Permit to include copper and/or zinc numeric limitations, as appropriate.
If the effluent is toxic, then we expect work to commence immediately with toxic effluent
samples. Failure to initiate work with toxic effluent samples during the study period is unacceptable and
will be considered a failure to make acceptable demonstration as cited above. We recommend a
minimum of three separate sampling events during the nine month period to definitively rule out copper
and/or zinc as causative effluent toxicants.

3
Please note that your actions to notify DWQ of prospective limit acceptance or to notify DWQ
of plan option(s) and subsequent submission of a plan are contingent upon two or more toxicity NPDES
permit limit violations occurring during a toxicity testing calendar quarter.
Also note that the WET limit will remain in your NPDES permit regardless of whether metals
are the source of effluent toxicity. The data resulting from your actions to disprove copper and/or zinc as
sources of effluent toxicity will determine whether NPDES Permit limits will be assigned for these
parameters. You are responsible for initiating actions to address these issues.
You may consider entering into a Special Order by Consent (SOC) with DWQ. A SOC provides
regulatory relief for specific NPDES permit limit violations and, if signed, will contain a requirement to
conduct a Toxicity Reduction Evaluation. The SOC will contain a compliance schedule, stipulated
penalties for failing to meet milestone activity dates and may contain upfront penalties to settle past
permit limit violations.
Additional information regarding the Division's copper and/or zinc action level policy can be
found at the following web site - http:/ /www.esb.enr.state.nc.us. Click on the "Aquatic
Toxicology" Unit and go to the prompt "DOWNLOADS" located at the bottom of the page. This web
site also contains EPA's "Toxicity Reduction Evaluation Guidance for Municipal Wastewater Treatment
Plants." Section 4 of this document contains pertinent information on Toxicity Identification
Evaluations.
If you have any questions concerning this correspondence, please contact me at [phone]
or Mr. Matt Matthews, Supervisor of the Aquatic Toxicology Unit at (91,9) 733-2136.
Sincerely,
Forrest Westall
Regional Water Quality Supervisor
cc: Asheville Regional Office
Susan Wilson-NPDES Unit
Tom Poe -Pretreatment
Lydia Mayo-USEPA Region IV, Atlanta Federal Center, 61 Forsyth St., SW, Atlanta, GA 30303
Central Files
Aquatic Toxicology Unit Files

r
State of North Carolina
Department of Environment and Natural Resources
Division of Water Quality
59 Woodfin Place
CERTIFIED MAIL
RETURN RECEIPT REQUESTED
Mr. Charles R. Summey
Town of Forest City
P.O. Box 728
Forest City, North Carolina 28043
SUBJECT:
June 21, 2001
NOTICE OF VIOLATION
Whole Effluent Toxicity (WET) Testing
Copper and Zinc Action Level Policy
NPDES Permit No. NC0025984
Town of Forest City WWTP
Rutherford County
Asheville, North Carolina 28801
Dear Mr. Summey:
This is to inform you that a review of your toxicity self -monitoring report form for the month of
April 2001 indicates a violation of the toxicity limitation specified in your NPDES Permit. You should
undertake necessary actions to eliminate or reduce effluent toxicity to acceptable levels.
In addition, this correspondence contains important information on the Division's Copper and
Zinc Action Level Policy which is triggered by two or more toxicity limit violations that occur during
the toxicity testing calendar quarter specified by the toxicity testing special condition of your NPDES
Permit. Attachments addressing policy implementation and a copy of the Division's Toxicity Reduction
Guidance have been included with this Notice of Violation.
You should initiate follow-up toxicity testing upon a single WET test failure which occurs
during the toxicity testing calendar quarter.
Your facility is currently monitoring for copper and/or zinc and is exceeding the action level for
these parameters. The policy states that whenever a facility experiences two or more toxicity limit
violations during a toxicity testing calendar quarter, the NPDES Permit will be modified to include
numeric limits for copper and/or zinc UNLESS the permittee provides one or more of the following:
1. Instream measurements of dissolved metal during low flow conditions that demonstrate
compliance with the Action Level standard
2. A revision of the prospective permit limit using improved inputs that in concert with
existing or additional monitoring data demonstrates compliance with the Action Level
standard
3. Toxicity Identification Evaluation (TIE) results that definitively rule out copper and/or zinc
as causes of effluent toxicity
4. Demonstration by an alternative method approved by the Division and EPA that copper
and/or zinc is not the cause of toxicity

2
The Division has evaluated your copper and/or zinc monitoring data. The Division has also
developed a prospective NPDES permit limit based on your facility's instream waste concentration, the
copper and/or zinc action level criterion and a translator procedure. Based on this data your prospective
copper permit limit is 99 µg/L.
The permittee, upon experiencing two or more toxicity limit violations during a toxicity
testing calendar quarter must either provide DWQ with:
a) Written notification indicating acceptance of the prospective copper
and/or zinc permit limit. Notification is due within 30 days after the date of
the second WET Notice of Violation.
OR
b) Written notification indicating your choice of option(s) as noted on page
one of this correspondence. Notification is due within 30 days after the date
of the second WET Notice of Violation.
Written notification (a or b above) shall be sent to:
North Carolina Division of Water Quality
Environmental Sciences Branch
Aquatic Toxicology Unit
1621 Mail Service Center
Raleigh, North Carolina 27699-1621
Please note that if you choose item b) above, you will be given nine months to submit
documentation that eliminates copper and/or zinc as causative effluent toxicants. Your final report
should be comprehensive and include all data used to support your conclusion(s). Should the data
indicate copper and/or zinc as the source of effluent toxicity or if the data are inconclusive as to copper
and/or zinc's role as a toxicity source, then the NPDES Permit will be reopened and the metal limits
specified above will be applied to the permit. The report is due nine months after the date of the second
WET Notice of Violation.
Three copies of the final report shall be submitted to:
North Carolina Division of Water Quality
Environmental Sciences Branch
Aquatic Toxicology Unit
1621 Mail Service Center
Raleigh, North Carolina 27699-1621
You should consider submitting the above correspondence certified mail.
Failure to notify DWQ of your acceptance of a copper and/or zinc limit, failure to notify
DWQ of your option selection or failure to make acceptable demonstration to DWQ that copper
and/or zinc are not causative effluent toxicants within the stated time frames will result in
reopening of the NPDES Permit to include copper and/or zinc numeric limitations, as appropriate.
Please note that your actions to notify DWQ of prospective limit acceptance or to notify DWQ
of plan option(s) and subsequent submission of a plan are contingent upon two or more toxicity NPDES
permit limit violations occurring during a toxicity testing calendar quarter.

3
Also note that the WET limit will remain in your NPDES permit regardless of whether metals
are the source of effluent toxicity. The data resulting from your actions to disprove copper and/or zinc as
sources of effluent toxicity will determine whether NPDES Permit limits will be assigned for these
parameters. You are responsible for initiating actions to address these issues.
You may consider entering into a Special Order by Consent (SOC) with DWQ. A SOC provides
regulatory relief for specific NPDES permit limit violations and, if signed, will contain a requirement to
conduct a Toxicity Reduction Evaluation. The SOC will contain a compliance schedule, stipulated
penalties for failing to meet milestone activity dates and may contain upfront penalties to settle past
permit limit violations.
Additional information regarding the Division's copper and/or zinc action level policy can be
found at the following web site - http: / /www.esb.enr.state.nc.us. Click on the "Aquatic
Toxicology" Unit and go to the prompt "AT Downloadable Files" located at the bottom of the page.
This web site also contains EPA's "Toxicity Reduction Evaluation Guidance for Municipal Wastewater
Treatment Plants." Section 4 of this document contains pertinent information on Toxicity Identification
Evaluations.
If you have any questions concerning this correspondence, please contact me at [phone]
or Mr. Matt Matthews, Supervisor of the Aquatic Toxicology Unit at [phone].
Sincerely,
Forrest Westall
Regional Water Quality Supervisor
ATTACHMENTS
cc: Asheville Regional Office (no attachments) /
Susan Wilson-NPDES Unit (no attachments) i/
Lydia Mayo-USEPA Region IV, Atlanta Federal Center, 61 Forsyth St., SW, Atlanta, GA 30303
(no attachments)
Central Files (no attachments)
Aquatic Toxicology Unit Files (no attachments)

Mc
ASSOC] ATES
April 1, 2003
Ms. Valery Stephens
NPDES Unit Point Source Branch
North Carolina Division of Water Quality
1617 Mail Service Center
Raleigh, North Carolina 27699-1617
Dear Ms. Stephens:
OOO? i _ tali
RE: NPDES Permit No. NC0025984
Town of Forest City WWTP
Rutherford County, North Carolina
On behalf of the Town of Forest City, and per your recent request in your letter to Mr.
Charles Summey, please fmd enclosed one (1) additional copy of the signed application form
that was included in the previously submitted NPDES Permit renewal package for the above
reference project.
If you have any questions or require any additional information, please feel free to
contact me at 828-252-0575.
Sincerely,
MCGILL ASSOCIATES, PlifA44i i, aide,
MICHAEL S. APKE, P.E.
Project Engineer
Enclosures
Cc: Chuck Summey, Town Manager
Scott Hoyle, Public Works Director
Keith Webb, P.E.
Projects/02728/vs01 apr3. doc
Engineering • Planning • Finance
McGill Associates, P.A. • P.D. Box 2259, Asheville, NC 28802 • 55 Broad Street, Asheville. NC 28801
828-252-0575 • FAX [phone]

FACILITY NAME AND PERMIT NUMBER: i
Forest City WWTP, NC0025984
PERMIT ACTION REQUESTED:
Renewal
RIVER BASIN:
Broad
SUPPLEMENTAL APPLICATION INFORMATION
PART F.INDUSTRIAL USER DISCHARGES AND RCRA/CERCLA WASTES
All treatment works receiving discharges from significant industrial users or which receive RCRA,CERCLA, or other remedial wastes must
complete part F.
GENERAL INFORMATION:
F.1. Pretreatment program. Does the treatment works have. or is subject ot. an approved pretreatment program?
E Yes ❑ No
F.2. Number of Significant Industrial Users (Sills) and Categorical Industrial Users (CIUs). Provide the number of each of the following types of
industrial users that discharge to the treatment works.
Number of non -categorical SIUs. 5
a.
b. Number of ClUs. 2
SIGNIFICANT INDUSTRIAL USER INFORMATION:
Supply the following information for each SIU. If more than one SIU discharges to the treatment works, copy questions F.3 through F.8 and
provide the information requested for each SIU.
F.3. Significant Industrial User Information. Provide the name and address of each SIU discharging to the treatment works. Submit additional pages
as necessary.
National Textiles
Name:
Mailing Address: 1331 West Main Street
Forest City, North Carolina 28043
F.4. Industrial Processes. Describe all the industrial processes that affect or contribute to the SIU's discharge.
Textile dye process waste water, wash down water, cooling water (HVAC), and domestic
F.5. Principal Product(s) and Raw Material(s). Describe all of the principal processes and raw materials that affect or contribute to the SIU's
discharge.
Principal T-Shirts, Sport Shirts
product(s):
Raw material(s): Cotton. Polyester fabric. dyes and chemicals
F.6. Flow Rate.
a Process wastewater flow rate. Indicate the average daily volume of process wastewater discharge into the collection system in gallons per
day (gpd) and whether the discharge is continuous or intermittent.
2,572.000 gpd ( X continuous or intermittent)
b. Non -process wastewater flow rate. Indicate the average daily volume of non -process wastewater flow discharged into the collection system
in gallons per day (gpd) and whether the discharge is continuous or intermittent.
Est. 15,000 gpd ( continuous or X intermittent)
F.7. Pretreatment Standards. Indicate whether the SIU is subject to the following:
a. Local limits E Yes ❑ No
b. Categorical pretreatment standards ❑ Yes No
If subject to categorical pretreatment standards, which category and subcategory?
NPDES FORM 2A Additional Information

SIGNIFICANT INDUSTRIAL USER INFORMATION:
Supply the following information for each SIU. If more than one SIU discharges to the treatment works, copy questions F.3 through F.8 and
provide the information requested for each SIU.
F.3. Significant Industrial User Information. Provide the name and address of each SIU discharging to the treatment works. Submit additional pages
as necessary.
Name: Eaton Corporation
Mailing Address: 240 Daniel Road
Forest City, North Carolina 28043
F.4. Industrial Processes. Describe all the industrial processes that affect or contribute to the SIU's discharge.
Process Waste water from automotive, air conditioning, and industrial hoses, cooling water, boiler
F.S. Principal Product(s) and Raw Material(s). Describe all of the principal processes and raw materials that affect or contribute to the SIU's
discharge.
Principal Low pressure air and hydraulic, Liquid propane gas and automotive, truck and bus air conditioning hoses, and
product(s):
power steering hoses
automotive
Raw material(s): Rubber. yarn, wire, inks, dyes, lubricants, release reagents
F.6. Flow Rate.
c. Process wastewater flow rate. Indicate the average daily volume of process wastewater discharge into the collection system in gallons per
day (gpd) and whether the discharge is continuous or intermittent.
Avg. 17,450 gpd (X continuous or intermittent)
d. Non -process wastewater flow rate. Indicate the average daily volume of non -process wastewater flow discharged into the collection system
in gallons per day (gpd) and whether the discharge is continuous or intermittent.
11.550 gpd ( continuous or X intermittent)
F.7. Pretreatment Standards. Indicate whether the SIU is subject to the following:
a. Local limits S Yes 0 No
b. Categorical pretreatment standards 0 Yes S No
If subject to categorical pretreatment standards, which category and subcategory?
NPDES FORM 2A Additional Information

SIGNIFICANT INDUSTRIAL USER INFORMATION:
Supply the following information for each SIU. If more than one SIU discharges to the treatment works, copy questions F.3 through F.8 and
provide the information requested for each SIU.
F.3. Significant Industrial User Information. Provide the name and address of each SIU discharging to the treatment works. Submit additional pages
as necessary
Name: Cone Mills Corporation
Mailing Address: 101 Depot Street
Forest City, North Carolina 28043
F.4. Industrial Processes. Describe all the industrial processes that affect or contribute to the SIU's discharge.
Fibers used in yarn making for other plants
F.S. Principal Product(s) and Raw Material(s). Describe all of the principal processes and raw materials that affect or contribute to the SIU's
discharge.
Principal product(s): Beamed and slashed logs used for other cone plants
Raw material(s): Water, "size material", cotton fiber
F.6. Flow Rate.
e. Process wastewater flow rate. Indicate the average daily volume of process wastewater discharge into the collection system in gallons per
day (gpd) and whether the discharge is continuous or intermittent.
0 gpd (X continuous or
intermittent)
f. Non -process wastewater flow rate. Indicate the average daily volume of non -process wastewater flow discharged into the collection system
in gallons per day (gpd) and whether the discharge is continuous or intermittent.
0 gpd ( continuous or X intermittent)
F.7. Pretreatment Standards. Indicate whether the SIU is subject to the following:
a. Local limits
0 Yes ❑ No
b. Categorical pretreatment standards ❑ Yes 0 No
If subject to categorical pretreatment standards, which category and subcategory?
Note:
Cone Mills ceased operation at this facility in February 2002. The Corporation asked to keep
the permit open. No flow is currently generated on -site.
NPDES FORM 2A Additional Information

SIGNIFICANT INDUSTRIAL USER INFORMATION:
Supply the following information for each SIU. If more than one SIU discharges to the treatment works, copy questions F.3 through F.8 and
provide the information requested for each SIU.
F.3. Significant Industrial User Information. Provide the name and address of each SIU discharging to the treatment works. Submit additional pages
as necessary.
Name: Simpus Foods International
Mailing Address: 212 Nuway Packing Road
Forest City, North Carolina 28043
F.4. Industrial Processes. Describe all the industrial processes that affect or contribute to the SIU's discharge.
Pork slaughter, processed foods
F.S. Principal Product(s) and Raw Material(s). Describe all of the principal processes and raw materials that affect or contribute to the SIU's
discharge.
Principal product(s): Pork sausage, fresh ham, chili, country ham, roast beef, cookies
Raw material(s):
F.6. Flow Rate.
Process wastewater flow rate. Indicate the average daily volume of process wastewater discharge into the collection system in gallons per
day (gpd) and whether the discharge is continuous or intermittent.
g.
Fat, live hogs, seasonings (salt, sugar, nitrates, nitrite, phosphates, liquid smoke. butter, flour, pepper)
100,000 gpd ( continuous or X intermittent)
h. Non -process wastewater flow rate. Indicate the average daily volume of non -process wastewater flow discharged into the collection system
in gallons per day (gpd) and whether the discharge is continuous or intermittent.
93,000
gpd ( continuous or X intermittent)
F.7. Pretreatment Standards. Indicate whether the SIU is subject to the following:
a. Local limits
b. Categorical pretreatment standards
® Yes
O Yes
O No
® No
If subject to categorical pretreatment standards, which category and subcategory?
NPDES FORM 2A Additional Information

SIGNIFICANT INDUSTRIAL USER INFORMATION:
Supply the following information for each SIU. If more than one SIU discharges to the treatment works, copy questions F.3 through F.8 and
provide the information requested for each SIU.
F.3. Significant Industrial User Information. Provide the name and address of each SIU discharging to the treatment works. Submit additional pages
as necessary.
Name: AGI Schutz
Mailing Address: 376 Pine Street Ext.
Forest City, North Carolina 28043
F.4. Industrial Processes. Describe all the industrial processes that affect or contribute to the SIU's discharge.
Manufacture point -of -purchase displays from woo. metal and vacuum formed plastic
F.S. Principal Product(s) and Raw Material(s). Describe all of the principal processes and raw materials that affect or contribute to the SIU's
discharge.
Principal product(s): Point of purchase displays
Raw material(s):
F.6. Flow Rate.
Process wastewater flow rate. Indicate the average daily volume of process wastewater discharge into the collection system in gallons per
day (gpd) and whether the discharge is continuous or intermittent.
Wood, particle board, masonite, laminate, metal, plastic, solvent paint, and powder paint
30,000 gpd ( continuous or X intermittent)
Non -process wastewater flow rate. Indicate the average daily volume of non -process wastewater flow discharged into the collection system
in gallons per day ;gpd) and whether the discharge is continuous or intermittent.
Est. 21,700
gpd ( continuous or X intermittent)
F.7. Pretreatment Standards. Indicate whether the SIU is subject to the following:
a. Local limits
b. Categorical pretreatment standards
Q Yes ❑ No
El Yes ❑ No
If subject to categorical pretreatment standards, which category and subcategory?
40 CFR 433 and 463
NPDES FORM 2A Additional Information

4
r
SIGNIFICANT INDUSTRIAL USER INFORMATION:
Supply the following information for each SIU. If more than one SIU discharges to the treatment works, copy questions F.3 through F.8 and
provide the information requested for each SIU.
F.3. Significant Industrial User Information. Provide the name and address of each SIU discharging to the treatment works. Submit additional pages
as necessary.
Name: Parker Hannifin
Mailing Address: P.O. Box 429 Pine Street
Forest City, North Carolina 28043
F.4. Industrial Processes. Describe all the industrial processes that affect or contribute to the SIU's discharge.
Manufacture hydraulic valves for industrial, mobile, government, and commercial applications
F.5. Principal Product(s) and Raw Material(s). Describe all of the principal processes and raw materials that affect or contribute to the SIU's
discharge.
Principal product(s): Hydraulic valves
Raw material(s): Gray cast iron, dura cast, dura bors, steel, aluminum. oils coolants
F.6. Flow Rate.
k. Process wastewater flow rate. Indicate the average daily volume of process wastewater discharge into the collection system in gallons per
day (gpd) and whether the discharge is continuous or intermittent.
11,000 gpd (X continuous or intermittent)
I. Non -process wastewater flow rate. Indicate the average daily volume of non -process wastewater flow discharged into the collection system
in gallons per day (gpd) and whether the discharge is continuous or intermittent.
Est. 700
gpd ( continuous or X intermittent)
F.7. Pretreatment Standards. Indicate whether the SIU is subject to the following:
a. Local limits
b. Categorical pretreatment standards
• Yes
® Yes
❑ No
❑ No
If subject to categorical pretreatment standards, which category and subcategory?
40 CFR 433.15
NPDES FORM 2A Additional Information

SIGNIFICANT INDUSTRIAL USER INFORMATION:
Supply the following information for each SIU. If more than one SIU discharges to the treatment works, copy questions F.3 through F.8 and
provide the information requested for each SIU.
F.3. Significant Industrial User Information. Provide the name and address of each SIU discharging to the treatment works. Submit additional pages
as necessary.
Name: Schneider Mills Incorporated
Mailing Address: 181 Schneider Drive
Forest City, North Carolina 28043
F.4. Industrial Processes. Describe all the industrial processes that affect or contribute to the SIU's discharge.
Textile weave plant
F.S. Principal Product(s) and Raw Material(s). Describe all of the principal processes and raw materials that affect or contribute to the SIU's
discharge.
Principal product(s): Woven material
Raw materal(s): Yam, acrylic size agent
F.6. Flow Rate.
m. Process wastewater flow rate. Indicate the average daily volume of process wastewater discharge into the collection system in gallons per
day (gpd) and whether the discharge is continuous or intermittent.
2,200 gpd ( continuous or X intermittent)
n. Non -process wastewater flow rate. Indicate the average daily volume of non -process wastewater flow discharged into the collection system
in gallons per day (gpd) and whether the discharge is continuous or intermittent.
18,200 gpd ( continuous or X intermittent)
F.7. Pretreatment Standards. Indicate whether the SIU is subject to the following:
a. Local limits
b. Categorical pretreatment standards
® Yes ❑ No
QYes ®No
If subject to categorical pretreatment standards, which category and subcategory?
NPDES FORM 2A Additional Information

SLUDGE MANAGEMENT PLAN
TOWN OF FOREST CITY WASTEWATER TREATMENT PLANT
RUTHERFORD COUNTY, NORTH CAROLINA
NPDES Permit # NC0025984
GENERAL
The Town of Forest City is located in Rutherford County, North Carolina, and currently
owns and operates two (2) wastewater treatment plants. The Town's primary treatment
plant is the Forest City WWTP (NPDES Permit No. NC0025984), which has a capacity
of 4.95 million gallons per day (MGD). This plant began operation in 1960, and was
originally designed with a capacity of 4.25 MGD. The capacity of the plant was
upgraded to 4.95 MGD in 1994. The last significant upgrade to the Forest City WWTP
was in 1998 when a sludge drying unit was added to the treatment process.
The Town's additional plant is the Riverstone Industrial Park WWTP (NPDES Permit
No. NC0087084), which is currently under construction and scheduled to be on-line in
January 2003. This plant will serve the businesses in the Riverstone Industrial Park, and
will initially have a capacity to treat 50,000 gallons per day (GPD) of wastewater.
SLUDGE GENERATION AND TREATMENT
Sludge at the Forest City WWTP is produced daily in the activated sludge processes, and
is collected from the secondary clarifiers and treated in two (2) aerobic digesters with a
total volume of 670,688 gallons. The two digesters provide a retention time of 13.5 days.
From the aerobic digesters, sludge is pumped at a rate of 375 GPM to a 2.0 meter belt
filter press where it is dewatered to approximately 14% solids. The dewatered sludge is
then transported to a dryer, which pasteurizes the sludge and dries it to approximately
95% solids. The current sludge drying process is run, on average, (3) three consecutive
days over a (2) two week period.
SLUDGE DISPOSAL
After the sludge has been pasteurized and dried to 95% solids, it is stored on -site in a silo,
and classified as a Class "A" product. The final product is currently made available to
local farmers and residents at no charge for land application. Historically, the Forest City
WWTP has produced approximately 800 tons of Class "A" product per year.