NCG500321_complete file-historical_20130703

e*.
NCDENR
North Carolina Department of Environment and
Division of Water Quality
Pat McCrory Thomas A. Reeder
Governor Acting Director
July 3, 2013
RECEIVED
Tony Setzer FILES
CENTRAL F
Shuford Yarns CENTRALFG
2815 1st Avenue SW
Hickory, NC 28602
SUBJECT: Compliance Evaluation Inspection
Dudley Shoals Plant -Cooling Water Discharge
Permit No: NCG500321
Caldwell County
Dear Mr. Setzer:
Natural Resources
John E. Skvarla, III
Secretary
On June 20, 2013, 1 conducted a compliance inspection associated with the cooling water
discharges at the Shuford Yarns Dudley Shoals Plant. You and Cecil Cline were present
for the inspection. The facility was found to be marginally compliant with permit
NCG500321. You will need to include the parameter Chemical Oxygen Demand (COD)
when sampling the effluent; see Footnote #4 in Part I A. (1) of your NCG500321 permit.
Please refer to the enclosed inspection report for further observations and comments. If
you or your staff have any questions, please call me at 828-296-4500.
Sincerely,
jl� 117-101
Linda Wiggs
Environmental Senior Specialist
Asheville Regional Office
Enclosure
cc: Central Files
Asheville Files
S:\SWP\Caldwell\Wastewater\General\Non-contact NCG50\Shuford-NCG500321\CEI. 6-20-2013.doc
SURFACE WATER PROTECTION —ASHEVILLE REGIONAL OFFICE
Location: 2090 U.S. Highway 70, Swannanoa, NC 28778 j\J One
erh
Phone: [phone]\FAX: [phone] c v � rthCHLOhric'l
Internet: www.ncwaterguality.orq 0�" �/�/6ltlmally

United States Environmental Protection Agency
Form Approved.
EPA Washington, D.C. 20460
OMB No. 2040-0057
Wafer Compliance Ins,12pdonn Rpport
Approval expires 8-31-98
Section A: National Data System Coding (i.e., PCS)
Transaction Code NPDES yr/molday Inspection Type Inspector Fac Type
20' I
1 t N t 2 Us3 I NCG500321 111 12I 13/06/20 117 18I S � 19 � �!
DJ =t
Remarks
211 I I I I I I I I I I I I I I I I I I I l I I I I I I I I I I I I L l l l l l l Jill l l _16
Inspection Work Days Facility Self -Monitoring Evaluation Rating B1 QA-------- -Reserved--
67 I 169 70 U 711j 72 tN 73 W 74 751 I I I I J I 180
Section B: Facility Data
Name and Location of Facility Inspected (For Industrial Users discharging to POTW, also include
Entry Time/Date
Permit Effective Date
POTW name and NPDES permit Number)
•
10:00 AM 13l06120
12/08/01
Dudley Shoals Plant
Exit Time/Date
Permit Expiration Date
5100 Bums Rd
Granite Falls NC 28630
11:50 AM 13/06/20
15/07/31
Name(s) of Onsite Representative(s)/Titles(s)/Phone and Fax Number(s)
Other Facility Data
Name, Address of Responsible OfficialMfie/Phone and Fax Number
Contacted
Mark E Hawes,PO Box 2228 Hickory NC 286032228//828-325-5428/8283255387 Yes
Section Q Areas Evaluated During Inspection (Check only those areas evaluated)
Permit Operations & Maintenance 0 Records/Reports Self -Monitoring Program
Facility Site Review Effluent/Receiving Waters
Section D: Summary of Finding/Comments (Attach additional sheets of narrative and checklists as necessary)
(See attachment summary)
Name(s) and Signature(s) of Inspector(s) Agency/Office/Phone and Fax Numbers Date
Linda S Wiggs ARO WQ/1828-296-4500 Ext.46531
Signature of Management Q A Reviewer Agency/Office/Phone and Fax Numbers
wk--� 14 ---
fZ2
EPA Form 3560-3 (Rev 9-94) Previous editions are obsolete.
Page # 1

NPDES yr/mo/day Inspection Type
3 I NCG500321 J1 12, 13/06/20 117 181 s I
(cont.)
Section D: Summary of Finding/Comments (Attach additional sheets of narrative and checklists as necessary)
The monitoring requirement for the cooling water discharge is twice a year for the following parameters:
{Effluent Limitations and Monitoring Requirements are listed in the table in Part I A.(1) of the permit)
*Flow -estimated at the end of the discharge pipe.
*Temperature -at the end of the discharge pipe and upstream and downstream of the discharge pipe.
(See Footnote 1 in the table)
*Total Residual Chlorine (TRC)-at the end of the discharge pipe. (See Footnote 2 in the table)
*pH -at the end of the discharge pipe.
*Chemical Oxygen Demand (COD) -at the end of the discharge pipe. (See Footnote 4 in the table)
The facility has not been sampling for COD, but needs to begin sampling for this parameter with the next
sampling event. COD is required because the facility uses water treatment chemicals in their discharge.
Biocide/Chemical Treatment Worksheets 101 were approved in 2007 for CWT-501, AWT-25 and CWT-804.
Page # 2

Permit: NCG500321
Inspection Date: 06/20/2013
Owner - Facility: Dudley Shoals Plant
Inspection Type: Compliance Sampling
Operations & Maintenance
Yes
No
NA NE
Is the plant generally clean with acceptable housekeeping?
■
Q
Q Q
Does the facility analyze process control parameters, for ex: MLSS, MCRT, Settleable Solids, pH, DO, Sludge ❑
❑
■ Q
Judge, and other that are applicable?
Comment:
Permit
Yes
No
NA NE
(If the present permit expires in 6 months or less). Has the permittee submitted a new application?
Q
Q
■ Q
Is the facility as described in the permit?
Q
Q
■ 0
# Are there any special conditions for the permit?
1100
Q
Is access to the plant site restricted to the general public?
■
❑
Q Q
Is the inspector granted access to all areas for inspection?
000
O
Comment:
Effluent Sampling
Is composite sampling flow proportional?
Is sample collected below all treatment units?
Is proper volume collected?
Is the tubing clean?
# Is proper temperature set for sample storage (kept at less than or equal to 6.0 degrees Celsius)?
Is the facility sampling performed as required by the permit (frequency, sampling type representative)?
Comment: Sampling shall be performed as indicated in permit under Part I A. (1).
Please pay special attention to the footnotes for the parameters listed in the table.
Yes No NA NE
0000
■000
■000
0000
0 0 0 M
0 M 0 0
Page # 3

QivShuford
Yarns
II February 2009
Certified Mail
Return Receipt Requested
NPDES Unit
North Carolina Division of Water Quality
1617 Mail Service Center
Raleigh, North Carolina 27699-1617
Subject: Engineer's Certification
NPDES Certificate of Coverage: NCG500321
Shuford Yarns, LLC — Dudley Shoals Facility
Caldwell County
Fro 1
Fro
DENR - WATER QUALITY
POINT SOURCE BRANCH
Attached please find the Engineer's Certification of the installation of a tablet dechlorination unit
at the referenced facility in accordance with the Authorization to Construct issued October 29, 2008. If you
have any questions or comments, please contact Mark Hawes at [phone], or via email at
mhawest7ashurtape.com.
Respectfully �Suubbmitted,
c '" V%
Jerry W. Eplin, PE
Cc: Allen Barwick
Khalid Majeed
Mark Hawes
1985 Tate Blvd SE, Box 54, Hickory, NC 28602
Corporate Phone: [phone] Corporate Fax: [phone]

Engineer's Certification
Shuford Yarns. LLC — Dudley Shoals Facility
NCG500321
I, DORY W EPu v , as a duly registered Professional Engineer in the State of North Carolina, having been
authorized to observe (ijeriodical weekly, full time) the construction of the following Dechlorination
wastewater treatment system SHupoe'n YA24/S !LL DUJO r SNoAIS 6=AGUTY
Project Name Location
Permittee hereby state that, to the best of my abilities, due care and diligence was used in the observation of the
construction such that the construction was observed to be built within substantial compliance and intent of the
approved plans and specifications.
2D
Signature i .cN C ° Registration No.��
aa Off' `- * ... ,•• .,
• ESS/ '<m
Date 2- / - 200!f O,y.6.1
SEAL
20144

Q� wA��9 Michael F. Easley, Governor
William G. Ross Jr., Secretary
CIS r North Carolina Department of Environment and Natural Resources
Coleen H. Sullins, Director
Division of Water Quality
October 29, 2008
Mr. Mark E. Hawes
Shuford Yams, LLC
1985 Tate Boulevard SE
Hickory, NC 28602
Subject: Issuance of Authorization to Construct (ATC)—NCG500321
Shuford Yams, LLC
Shuford Yams, Dudley Shoals Facility
5100 Bums Road
Granite Falls, NC 28630
Caldwell County
Dear Mr. Hawes:
In accordance with your application for an ATC, dated September 26, 2008, the Division is issuing this ATC
authorizing the construction of an on -site Dechlorination system to treat Boiler Cooling Tower Blowdown water
or similar wastewater from the Shuford Yams, Dudley Shoals Facility located at 5100 Burns Road, Granite Falls,
Caldwell County, NC. The Dechlorination system will utilize Sodium Sulfite for treatment purposes prior to
discharging to receiving water designated as the Upper Little River, a class WS-IV water in the Catawba River
Basin. This discharge shall be in accordance with the effluent limitations, monitoring requirements, and other
conditions set forth in Parts I, II,111 and IV of General Permit NCG500000.
If any parts, measurement frequencies or sampling requirements contained in this general permit are unacceptable
to you, you have the right to submit an individual permit application and letter requesting coverage under an
individual permit. Unless such demand is made, this decision shall be final and binding.
This Authorization to Construct is issued in accordance with Part III, Paragraph 2 of NPDES Permit No.
NCG500000, and shall be subject to revocation unless the wastewater treatment facilities are constructed in
accordance with the conditions and limitations specified in Permit No. NCG500000.
In the event that the facilities fail to perform satisfactorily, including the creation of nuisance conditions, the
Permittee shall take immediate corrective action, including those as may be required by the Division, such as the
construction of additional or replacement wastewater treatment or disposal facilities.
The Asheville Regional Office, telephone number [phone], shall be notified at least forty-eight (48) hours
in advance of operation of the installed facilities so that an in -place inspection can be made. Such notification to
the Surface Water Regional supervisor shall be made during the normal office hours from 8:00 a.m. until 5:00
p.m. on Monday through Friday, excluding State Holidays.
Upon completion of construction and prior to operation of this permitted facility, a certification must be received
certifying that the permitted facility has been installed in accordance with this ATC and the approved plans and
specifications. Mail the Certification to the NPDES Unit, 1617 Mail Service Center, Raleigh, NC 27699-1617. A
copy of the approved plans and specifications shall be maintained on file by the Permittee for the life of the
facility.
Carolina
iura!!�
North Carolina Division of Water Quality 1617 Mail Service Center Raleigh, NC 27699-1617 Phone [phone] Customer Service
Internet: www.ncwaterquality.org Location: 512 N. Salisbury St. Raleigh, NC 27604 Fax [phone]
An Equal Opportunity/AffirmaNe Action Employer — 50°% Recycled1100/6 Post Consumer Paper

Failure to abide by the requirements contained in this ATC may subject the Permittee to an enforcement action by
the Division of Water Quality in accordance with North Carolina General Statute 143-215.6A to 143-215.6C.
This ATC is not transferable except after notice to the Division. The Division may require modification or
revocation and reissuance of the CoC. Part II, EA. addresses the requirements to be followed in case of change of
ownership or control of this discharge.
The issuance of this ATC does not preclude the Permittee from complying with any and all statutes, rules,
regulations, or ordinances 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 Federal or Local other governmental
permit that may be required.
If you have any questions or need additional information, please contact Bob Guerra at [phone].
Sincerely
JA Coleen H. Sullins
cc: Central Files
Asheville Regional Office/Surface Water Protection Section
Asheville DEH - James Adams
2090 U.S. Highway 70
Swannanoa, North Carolina 28778
NPDES Unit File

Qi'Shuford
Yarns ,LC.
26 September 2008
North Carolina Division of Water Quality
Construction Grants & Loans Section
1633 Mail Service Center
Raleigh, NC 27699-1633
RE: Fast -Track Dechlorination Application
Shufo Yarns — Dudley Shoals Facility
2
C500321" A16 &5n3 L /
RECEIVED
0,01 JCTKXV GRANTS &
LOAV' S[CpON
Enclosed, please find one original and one copy of the referenced application.
Authorization to Construct the referenced dechlorination system is hereby requested.
If you have questions or require further information, please contact Mark Hawes at (828)
325-5428, or via email at mhawesasb]g=e.com S 1A
10 -I
Sincerely,
kk_V'C)�'_a
4
Khalid Majeed
Vice President of
cc: Mark Haw
Jerry Eplit
�y39�
i
L
��I? /jew,J-ea»y�
NC E',ijjanMih�,
U
Th, _j /-;�f Qh Tc
-lei h,n
1985 Tate Blvd SE, Box 54, Hickory, NC 28602
Corporate Phone: [phone] Corporate Fax: [phone]

North Carolina Division Of Water Quality
Construction Grants & Loans Section
Dechlorination Facilities Fast -Track
Authorization To Construct (ATC) Application Form
(To Be Used On and After August I, 2007)
Date: 09/15/08
Permittee/Owner Name: SHUFORD YARNS, LLC
Contact Person: MARK HAWES
Address: 1985 TATE BLVD, SE
HICKORY NC 28602
Telephone Number: [phone]
NPDES Permit Number: NC500321
Facility Name: SHUFORD YARNS, LLC
Facility Address (Physical Location): 5100 BURNS ROAD
GRANITE FALLS, NC
County project is located in: CALDWELL
Name of receiving stream: UPPER LITTLE RIVER
Name of river basin: CATAWBA RIVER BASIN
OCT 20081
Professional Engineer of Record: Jerry W. Eplin
Engineering Firm: N/A company employee
Address: P.O. Box 1530
Hickory, NC 28603
Telephone Number: [phone]
Date Issued: 08/01/2007
Project Description: INSTALLATION OF DECHLORINATION FACILITIES
Type of dechlorinating agent used (chemical): Sodium Sulfite (Na2SO3)
If other, please specify:

North Carolina Division Of Water Quality
Construction Grants & Loans Section
Dechlorination Facilities Fast -Track Authorization To Construct (ATC) Application Cover
(To Be Used On and After August 1, 2007)
INSTRUCTIONS: Indicate that you have included the following list of required application package items by
signing your initials in the space provided next to each item. Failure to submit all required items will lead to return
of the permit application.
{q /►/ A. Application Form - Submit one original and one copy of the completed and appropriately
�`— executed application form. Any changes to this form will result in the application being returned.
The Division of Water Quality (the Division) will only accept application packages that have been
fully completed with all applicable items addressed. You DO NOT need to submit detailed plans
and specifications at this time. Plans and specifications shall be maintained on -site.
'�eeN
B. Certification Form -Submit the completed engineers certification form signed and sealed by a
professional engineer registered in the state of North Carolina.
C. Designated Representative - If the application is being filed by a party other than the owner, a
letter from the owner designating the applicant as his/her authorized representative must be
included.
D. Read, understood, and followed the Dechlorination System Minimum Design Criteria
(adopted 4/18/03 and as subsequently amended).
The completed application package should be sent to the following addr V
North Carolina Division Of Water Quality
Construction Grants & Loans Section
i�if'!STAI��UC'TcIOc/Nr}G/RA
1 10AN SECT ION
By U.S. Postal Service: By Courier/Special Delivery:
1633 Mail Service Center 2728 Capital Blvd
Raleigh, NC 27699-1633 Raleigh, NC 27604
Phone: [phone]
Fax: [phone]
For more information, visit our website at http://www.nccgl.nettEngineering/plans.htmi

North Carolina Division Of Water Quality RECEIVED
Construction Grants & Loans Section
2008
Dechlorination Facilities Fast -Track
Authorization To Construct (ATC) Certification C(h'i3TAUC ONGf#w
(To Be Used On and After August 1, 2007) LOMSECTION
Professional Engineer's Certification:
I, Jerry W. Eolin, attest that this application for Shuford Yarns has been reviewed by me and is accurate,
complete, and consistent with the information in the engineering plans, calculations, and all other
supporting documentation. I further attest that the proposed design has been prepared in accordance with
all applicable regulations and Minimum Design Criteria for Dechlorination Facilities, adopted April 18,
2003. Although certain portions of this submittal package may have been prepared by other
professionals, inclusion of these materials under my signature and seal signifies that I have reviewed this
material and have judged it to be consistent with the proposed design.
NOTE: In accordance with NC General Statutes 143-215.6A and 143-215.613, any person who knowingly
makes any false statement, representation, or certification in any application shall be guilty of a Class 2
misdemeanor which may include a fine not to exceed $10,000 as well as civil penalties up to $25,000 per
violation. Furthermore, failure to design the above referenced facilities in accordance with Minimum
Design Criteria for Dechlorination Facilities and good engineering practice could subject you to
disciplinary action by the North Carolina Board for Professional Engineers and Land Surveyors.
, , t to V G a 6'416G°
North Carolina Professional Engineer's seal, signature, and date: CAR
�.'.QoFgSS%p•'Z�2�
4 y
>'r
0.
.•
Signature:
l���l �ct�� Re °es°��rerte
Date: Registration No.: 20144
Applicant's Certification:
I, Khalid Maieed, attest that this application for Shuford Yarns has been reviewed by me and is accurate
and complete to the best of my knowledge. By signing this certification I certify that facilities have been
designed in accordance with Minimum Design Criteria for Dechlorination Facilities, adopted April 18,
2003, and commit to insure construction proceeds in accordance with said criteria.
NOTE: In accordance with NC General Statutes 143-215.6A and 143-215.613, any person who knowingly
makes any false statement, representation, or certification in any application shall be guilty of a Class 2
misdemeanor which may include a fine not to exceed $10,000 as well as civil penalties up to $25,000 per
violation.
Signature: 1� ' �6 0
Date:

Qi'Shuford
Yarns RECEIVED
OCT 2008
CNTR
26 September 2008 C4 SECT
North Carolina Division of Water Quality
Construction Grants & Loans Section
1633 Mail Service Center
Raleigh, NC 27699-1633
�-1 1 4
RE: Fast -Track Dechlorination Application
Shuford Yarns — Dudley Shoals Facility -
NC500321
Enclosed, please find one original and one copy of the referenced application.
Authorization to Construct the referenced dechlorination system is hereby requested.
If you have questions or require further information, please contact Mark Hawes at (828)
325-5428, or via email at mhawesashurtape.com
Sincerely,
Khalid Majeed
Vice President of Manufacturing
cc: Mark Hawes
Jerry Eplin
1985 Tate Blvd SE, Box 54, Hickory, NC 28602
Corporate Phone:[phone] Corporate Fax:[phone]

e�A
NCDENR
North Carolina Department of Environment and Natural Resources
Division of Water Quality
Michael F. Easley, Governor William G. Ross, Jr., Secretary
Coleen H. Sullins, Director
July 23, 2007
Mark E. Hawes
Shuford Yarns, LLC
1985 Tate Boulevard SE
Hickory, NC 28602
Subject: Renewal of coverage / General Permit NCG500000
Dudley Shoals Facility
Certificate of Coverage NCG500321
Caldwell County
Dear Permittee:
In accordance with your renewal application [received on February 1, 20071, the Division is renewing
Certificate of Coverage (CoC) NCG500321 to discharge under NCG500000. This CoC is issued pursuant to the
requirements of North Carolina General Statue 143-215.1 and the Memorandum of Agreement between North
Carolina and the US Environmental Protection agency dated May 9, 1994 [or as subsequently amended].
If any parts, measurement frequencies or sampling requirements contained in this General Permit are
unacceptable to you, you have the right to request an individual permit by submitting an individual permit
application. Unless such demand is made, the certificate of coverage shall be final and binding.
Please take notice that this Certificate of Coverage is not transferable except after notice to the
Division. The Division may require modification or revocation and reissuance of the certificate of coverage.
This permit does not affect the legal requirements to obtain other permits which may be required by
the Division of Water Quality or permits required by the Division of Land Resources, Coastal Area
Management Act or any other Federal or Local governmental permit that may be required.
If you have any questions concerning the requirements of the General Permit, please contact Jim
McKay [919 733-5083, extension 595 or [e-mail].
Sincerely,
for Coleen H. Sullins
cc: Central Files
Asheville Regional Office / Surface Water Protection
NPDES file
1617 Mail Service Center, Raleigh, North Carolina 27699-1617 One
512 North Salisbury Street, Raleigh, North Carolina 27604 NorthCarohna
Phone: [phone] / FAX [phone] / Internet: www.ncwaterquality.org {�/�/ a "
ahma //y
An Equal Opportunity/Affirmative Action Employer - 50% Recycled/l 00% Post Consumer Paper

STATE OF NORTH CAROLINA
DEPARTMENT OF ENVIRONMENT AND NATURAL RESOURCES
DIVISION OF WATER QUALITY
GENERAL PERMIT NCG500000
CERTIFICATE OF COVERAGE NCG500321
TO DISCHARGE NON -CONTACT COOLING WATER, COOLING TOWER AND BOILER
BLOWDOWN, CONDENSATE AND SIMILAR WASTEWATERS 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,
Shuford Yarns, LLC
is hereby authorized to discharge from a facility located at
Dudley Shoals Facility
5100 Burns Road
Granite Falls
Caldwell County
to receiving waters designated as the Upper Little River in subbasin 30832 of the Catawba
River Basin in accordance with the effluent limitations, monitoring requirements, and
other conditions set forth in Parts I, II, III and IV hereof.
This certificate of coverage shall become effective August 1, 2007.
This Certificate of Coverage shall remain in effect for the duration of the General Permit.
Signed this day July 23, 2007.
for Coleen H. Sullins, Director
Division of Water Quality
By Authority of the Environmental Management Commission

QrShuford
Yarns L,C
30 January 2007
Mr. Charles H. Weaver
NC DENR / DWQ / NPDES
1617 Mail Service Center
Raleigh, North Carolina 27699-1617
RE: NCG500000 Renewal Application
Shuford Yarns, LLC, Dudley Shoals Facility
5100 Bums Road
Granite Falls, North Carolina
Certificate of Coverage (COC) NCG500321
Enclosed, please find the complete renewal information for the referenced discharge
permit. Also enclosed are completed Biocide 101 forms along with supporting
information as required.
The Shuford Yarns, LLC, Dudley Shoals Facility (the Facility) discharges water from air
wash stations, and from cooling towers, under the referenced discharge permit. Water
treatment for the discharges is currently contracted to Elements Illustrated, Inc. The
primary water treatment chemicals are as follows:
• CWT-501 {active ingredient: Poly [oxyethylene (dimethyliminio) ethylene
(dimethyliminio) ethylene dichloride])
• AWT-25 {active ingredient: Poly [oxyethyethylene (dimethyliminio) ethylene
(dimethyliminio) ethylene dichloride]]
• AWT-804 (active ingredient: Acrylic Terpolymer)
Note that the CWT-501 is used in both the cooling towers and the air washes at the
facility. AWT-25 is used is used in just the air washes. AWT-804 is only used in the
cooling towers.
To complete the Biocide 101 forms, stream flow data was obtained from the USGS. A
copy of the information provided by the USGS is attached.
1985 Tate Blvd SE, Box 54, Hickory, NC 28602
Corporate Phone: [phone] Corporate Fax: [phone]

Mr. Charles H. Weaver
30 January 2007
Page 2 of 2
Shuford Yarns understands that the new permit will include a chlorine limitation. To
comply with such a standard, steps to dechlorinate the discharge will be required. The
Facility requests that the permit specifically state that up to 18 months will be allowed to
comply with any such standard, to allow time to design and construction such
dechlorination facilities as will be required.
Finally, on 23 June 2006, an application was submitted requesting that the company
name be changed from Shuford Mills, to Shuford Yarns. As of yet, we have not received
documentation that this change has taken place. This renewal application was completed
under the name "Shuford Yarns".
If you have further question or comment, please contact me at [phone], or via
email a mhawesaa shurtape.com.
Sincerely,
Shuford Yarns, LLC
Mark E. Hawes, PE
cc: Jerry Eplin
Khalid Majeed
Ron Davis

A
NCDENR
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
NOTICE OF RENEWAL INTENT
Application for renewal of existing coverage under General Permit NCG500000
Existing Certificate of Coverage (CoC): NCG500 321
(Please print or type)
1) Mailing address' of facility owner/operator:
Company Name SNoFORb YARNsd 1--I-L
Owner Name 5AuF0RD YARNS, LL.G CA7741' MAQr—>ynwss�
Street Address t 9 35- TA 1-6 uit) y 5 �, QOA 55
City H f G2 ^r
K oY State Iv (_ ZIP Code 2 k (.0Z
Telephone Number R29 324-4265 Fax: 9'2-g 32N'yz3.S
Email address f h c{ WC s (a 6 hvr Jalec mart
` Address to which all permit correspondence should be mailed
2) Location of facility producing discharge:
Facility Name ';HuP-oRp YAQA/S d OVDL6t' SHOAL5 FAc-jLi T—
Facility Contact Tpciini e AI Co'vr/iCT: M AP-1L Ht1wt5
Street Address 5'tO0 AcvRAy5 (LOAD
City C// RAN t"rL �� 1 5 State N L ZIP Code 2 W3D
County l.-. ALo I✓FLL.
Telephone Number g2$ fir{ 6 2 34 Z Fax: a2 9
Email address Mhai c @5l� rla� rnM
3) Description of Discharge:
a) Is the discharge directly to the receiving stream? -K Yes ❑ No
(If no, submit a site map with the pathway to the potential receiving waters clearly marked. This includes tracing the pathway of the
storm sewer to the discharge point, if the storm sewer is the only viable means of discharge.)
b) Number of discharge outfalls (ditches, pipes, channels, etc. that convey wastewater from the property):
001..
c) What type of wastewater is discharged? Indicate which discharge points, if more than one.
%,Non -contact cooling water
Outfall(s) #: 6<0 1
❑ Boiler Blowdown Outfall (s) #:
Page 1 of 3

NCG500000 renewal application
,"Cooling Tower Blowdown
❑ Condensate
❑ Other
(Please describe "Other")
Outfall (s) #: Oo 1
Outfall (s) #:
Outfall (s) #:
d) Volume of discharge per each discharge point (in GPD):
#001: Z #002: #003: #004
4) Please check the type of chemical [s] added to the wastewater for treatment, per each separate discharge
point (if applicable, use separate sheet):
❑ Chlorine XBiocides Corrosion inhibitors O Algaecide ❑ Other
❑.None
5) If any box in item (4) above [other than None] was checked, a completed Biocide 101 Form and
manufacturers' information on the additive must be submitted to the following address for approval:
NC DENR / DWQ / Environmental Sciences Section
Aquatic Toxicology Unit
1621 Mail Service Center
Raleigh, NC 27699-1621
6) Is there any type of treatment being provided to the wastewater before discharge (i.e., retention ponds,
settling ponds, etc.)? ❑ Yes XNo
(If yes, please include design specifics (i.e., design volume, retention time, surface area, etc.) with submittal package. Existing
treatment facilities should be described in detail. )
7) Discharge Frequency:
a) The discharge is: C Continuous Intermittent ❑ Seasonal* f
i) If the discharge is intermittent, describe when the discharge will occur: Occu.s � -1 ,
?:14r s �ackt 4s�t of tV104 MOWAQWn 'S APejeci &-SJOn nmm�Tv. ^�
ii) *Check the month(s) the discharge occurs: ❑ Jan ❑ Feb ❑ Mar. ❑ Apr ❑ May ❑ Jun ❑ Jul
❑ Aug. ❑ Sept. ❑ Oct. ❑ Nov. ❑ Dec.
b) How many days per week is there a discharge? %
c) Please check the days discharge occurs: Z Sat. ULSun. ®Mon. KTue. 6i Wed. ® Thu. IXFri.
8) Receiving stream[s]:
a) To what body or bodies of water (creek, stream, river, lake, etc.) does the facility discharge
wastewater? If the site discharges wastewater to a separate storm sewer system (4S), name the
operator of the 4S (e.g. City of Raleigh). Upee, L-Al c Lyer
b) Stream Classification:
Page 2 of 3

NCG500000 renewal application
Additional Application Requirements:
The following information must be included in triplicate [original + 2 copies] with this application or it will
be returned as incomplete.
➢ Site snap. If the discharge is not directly to a stream, the pathway to the receiving stream must
be clearly indicated. This includes tracing the pathway of a storm sewer to its discharge point.
➢ Authorization for representatives. If this application will be submitted by a consulting
engineer (or engineering firm), include documentation from the Permittee showing that the
consultant submitting the application has been designated an Authorized Representative of the
applicant.
Certification
I certify that I am familiar with the information contained in this application and that to the best of my
knowledge and belief such information is true, complete, and accurate.
Printed Name of Person Signing: \/-.\ \-� JCL 1 1) %/ 16 3 �e � -
Title:
;a
1-3a-67
(Signature of Applicant) (Date Signed)
North Carolina General Statute 143-215.6 b (i) provides that:
Any person who knowingly makes any false statement, representation, or certification in any application, record, report, plan or other document
filed or required to be maintained under Article 21 or regulations of the Environmental Management Commission implementing that Article, or who
falsifies, tampers with or knowingly renders inaccurate any recording or monitoring device or method required to be operated or maintained under
Article 21 or regulations of the Environmental Management Commission implementing that Article, shall be guilty of a misdemeanor punishable by
a fine not to exceed $25,000, or by imprisonment not to exceed six months, or by both. (18 U.S.C. Section 1001 provides a punishment by a fine
of not more than $25,000 or imprisonment not more than 5 years, or both, for a similar offense.)
This Notice of Renewal Intent does NOT require a separate fee.
The permitted facility already pays an annual fee for coverage under NCG500000.
Mail the original and two copies of the entire package to:
Mr. Charles H. Weaver
NC DENR / DWQ / NPDES
1617 Mail Service Center
Raleigh, North Carolina 27699-1617
Page 3 of 3

r
,
t
rri CT
KEY
Aw Air Wash Location
cT Cooling Tower Location
oL Discharge Location
Discharge travels through above aground
and underground piping to discharge
location.
CO
6 8 78 1 All locations are approximate
DL
r
CT
r , AW v. I '� � 4' � • I
S'
j
",5 �� rf
i1411N[: VIJ,.nnnVr: ,.wn��vn m,v
Shuford Yems NPOES PERMIT N SDDl2
Drenwx BY: JWE PERMIT RENEWAL
PROJECT NUMBER: Dudley Noroals PlantZ�y
Uudley Slwels, s, North Carolina
SCALE a ouo a

SHURFORD YARNS
Dudley Shoals
Water Treatment Chemicals and Discharges
Chemicals
FEstimated
Current
Makeup
Estimate of
Name
Discharge
Capacity of
Water
CWT-501
CWT-804
AWT-25 dose
Point
System
(gallons/day)
Discharge
dose 1.6
Usage
dose 0.4 Ibs I
Usage
1.776 Ibs I
Usage
(Gallons)
Rate
Ibs/1000 gallons
(grams/d)
1000 gallons
(grams/d)
1000 gallons
(grams/d)
(gallons/day)
system water
makeup water
system water
Cooling Tower A/B
Outfall 001
750
3209
321
YES, CWT-501
544.8
YES, CWT-804
582.7
NO, AWT-25
IS USED
IS USED
IS NOT USED
Cooling Tower C
Outfall 001
1000
3514
351
YES, CWT-501
726.4
YES, CWT-804
638.1
NO, AWT-25
IS USED
IS USED
IS NOT USED
Cooling Tower D
Outfall 001
250
500
250
YES, CWT-501
181.6
YES, CWT-804
90.8
NO, AWT-25
IS USED
IS USED
IS NOT USED
Cooling Tower E
Outfall 001
1000
5027
- 503
YES, CWT-501
726.4
YES, CWT-804
912.9
NO, AWT-25
IS USED
IS USED
IS NOT USED
Airwash #1
Outfall 001
500
250
YES, CWT-501
363.2
NO, CWT-804
YES, AWT-25
403.5
IS USED
IS NOT USED
IS USED
Airwash #2
Outfall 001
500
250
YES, CWT-501
363.2
NO, CWT-804
YES, AWT-25
403.5
IS USED
IS NOT USED
IS USED
Airwash #3
Outfall 001
1200
250
YES, CWT-501
871.7
NO, CWT-804
YES, AWT-25
968.4
IS USED
IS NOT USED
IS USED
TOTALS:
VOLUMES FOR TOWERS
5200 2175
3000 1425
VOLUMES FOR AIR WASHES 2200 750
3777.3
2224.5
1775.5

—i
Y
August 16, 2006
Allen Barwick
Shuford Yams, I.LC
1985 Tate Blvd. S.E., Boa 54
Hickory, NC 28602
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 Duality
Subject NPDES Permit Modification
Permit NCG500321
Shuford Yams LLC - Dudley Shoal
formerly Shuford Mills Inc
Caldwell County
Dear Mr. Barwick.
Division personnel have reviewed and approved your change of address request of the subject permit, received on
June 27, 2006. This permit modification documents the change in ownership.
Please find enclosed the revised permit including a copy of the Certificate of Coverage, copy of the General
Wastewater Discharge Permit NCG500000, and a copy of a Technical Bulletin for General Wastewater Discharge
Permit NCG500000. 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 or 350.
Sincerely,
FA' I V1, �
cc Central Files
Asheville Regional Office, Surface Water Protection
NPDES Unit File
N�am� `trCarolina
� iff/17!!y
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]
An Equal OpportunitylAfitmative Action Employer— 50% Recycled/10% Post Consumer Paper

STATE OF NORTH CAROLINA
DEPARTMENT OF ENVIRONMENT AND NATURAL RESOURCES
DIVISION OF WATER QUALITY
GENERAL PERNIIT NO. NCG500000
CERTIFICATE OF COVERAGE No. NCG500321
TO DISCHARGE NON -CONTACT COOLING WATER, COOLING TOWER AND BOILER BLOWDOWN,
CONDENSATE AND SIMILAR WASTEWATERS UNDER THE
NATIONAL POLLUTANT DISCHARGE ELEVIINATION 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,
is hereby authorized to discharge
SHUFORD YARNS, LLC
COOLING TOWER BLOWDOWN
water or similar wastewater from a facility located at
SHURFORD YARNS, LLC — DUDLEY SHOAL
NCSR 1749 BURNS ROAD
DUDLEY SHOALS
CALDWELL COUNTY
to receiving waters designated as the Upper Little River, a class WS-IV water, in the Catawba River Basin in
accordance with the effluent limitations, monitoring requirements, and other conditions set forth in Parts I, II, III, and
IV of General Permit No. NCG500000 as attached
This certificate of coverage shall become effective August 16, 2006.
This Certificate of Coverage shall remain in effect for the duration of the General Permit.
Signed this day August 16, 2006.
*LAlan W. Klimek, P.E., Director
Division of Water Quality
By Authority of the Environmental Management Commission

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
July 26, 2002
MARK HAWES
SHUFORD MILLS INC-DUDLEY SHOAL
PO BOX 2228
HICKORY, NC 28601
WA
1�•
NOOK
NC ENR
NORTH CAROLINA DEPARTMENT OF
ENVIRONMENT AND NATURAL RESOURCES
Subject: Reissue - NPDES Wastewater Discharge Permit
Shuford Mills Inc -Dudley Shoal
COC Number NCG500321
Caldwell County
Dear Permittee:
In response to your renewal application for continued coverage under general permit NCG500000, the Division of
Water Quality (DWQ) is forwarding herewith the reissued wastewater general permit Certificate of Coverage
(COC). This COC is reissued pursuant to the requirements of North Carolina General Statute 143-215.1 and the
Memorandum of Agreement between the state of North Carolina and the U.S. Environmental Protection Agency,
dated May 9, 1994 (or as subsquently amended).
The following information is included with your permit package:
* A copy of the Certificate of Coverage for your treatment facility
* A copy of General Wastewater Discharge Permit NCG500000
* A copy of a Technical Bulletin for General Wastewater Discharge Permit NCG500000
Your coverage under this general permit is not transferable except after notice to DWQ. The Division. may require
modification or revocation and reissuance of the Certificate of Coverage. This permit does not affect the legal
requirements to obtain other permits which may be required by DENR or relieve the permittee from responsibility
for compliance with any other applicable federal, state, or local law rule, standard, ordinance, order, judgment, or
decree.
If you have any questions regarding this permit package please contact Aisha Lau of the Central Office Stormwater
and General Permits Unit at [phone], ext. 578
Sincerely,
for Alan W. Klimek, P.E.
cc: Central Files
Stormwater & General Permits Unit Files
Asheville Regional Office
1617 Mail Service Center, Raleigh, North Carolina 27699-1617 Telephone [phone] FAX [phone]
An Equal Opportunity Affirmative Action Employer 50% recycled/ 10% post -consumer paper

STATE OF NORTH CAROLINA
DEPARTMENT OF ENVIRONMENT AND NATURAL RESOURCES
DIVISION OF WATER QUALITY
GENERAL PERMIT NO. NCG500000
CERTIFICATE OF COVERAGE No. NCG500321
TO DISCHARGE NON -CONTACT COOLING WATER, COOLING TOWER AND BOILER
BLOWDOWN, CONDENSATE AND SRVIILAR WASTEWATERS 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,
is hereby authorized to discharge
SHUFORD MILLS, INC.
COOLING TOWER BLOWDOWN
water or similar wastewater from a facility located at
SHUFORD MILLS INC-DUDLEY SHOAL
NCSR 1749 BURNS ROAD
DUDLEY SHOALS
CALDWELL COUNTY
to receiving waters designated as the Upper Little River, a class WS-IV water, in the Catawba River Basin in
accordance with the effluent limitations, monitoring requirements, and other conditions set forth in Parts I, II, III,
and IV of General Permit No. NCG500000 as attached.
This certificate of coverage shall become effective August 1, 2002.
This Certificate of Coverage shall remain in effect for the duration of the General Permit.
Signed this day July 26, 2002.
for Alan W. Klimek, P.E., Director
Division of Water Quality
By Authority of the Environmental Management Commission

State of North Carolina
Department of Environment
and Natural Resources
Division of Water Quality
Michael F. Easley, Governor
William G. Ross Jr., Secretary
Gregory J. Thorpe, Ph.D., Acting Director
11/26/2001
THOMAS Z GUTHRIE
SHUFORD MILLS INC-DUDLEY SHOAL
PO BOX 2228
HICKORY, NC 28601
1 ••
NCDENR
NORTH CAROLINA DEPARTMENT OF
ENVIRONMENT AND NATURAL RESOURCES
Subject: NPDES Wastewater Permit Coverage Renewal
Shuford Mills Inc-dudley Shoal
COC Number NC0500321
Caldwell County
Dear Permittee:
Your facility is currently covered for wastewater discharge under General Permit NCG500000. This permit expires
on July 31, 2002. Division of Water Quality (DWQ) staff is in the process of rewriting this permit with a
scheduled reissue in the summer of 2002. Once the permit is reissued, your facility would be eligible for continued
coverage under the reissued permit.
In order to assure your continued coverage under the general permit, you must apply to the DWQ for renewal of
your permit coverage. To make this renewal process easier, we are informing you in advance that your permit
coverage will be expiring. Enclosed you will find a general permit coverage renewal application form. This
will serve as your application for renewal of your permit coverage. The application must be completed and
returned with the required information by February 01, 2002 in order to assure continued coverage under the
general permit. There is no renewal fee associated with this process. Your facility will be invoiced for the annual
permit fee at a later date.
Failure to request renewal within this time period may result in a civil assessment of at least $250.00. Larger
penalties may be assessed depending on the delinquency of the request. Discharge of wastewater from your facility
without coverage under a valid wastewater NPDES permit would constitute a violation of NCGS 143-215.1 and
could result in assessments of civil penalties of up to $10,000 per day.
If the subject wastewater discharge to waters of the state has been terminated, please complete the enclosed
rescission request form. Mailing instructions are listed on the bottom of the form. You will be notified when the
rescission process has been completed.
If you have any questions regarding the permit coverage renewal procedures please contact the Asheville Regional
Office at 828-251-6208 or Delonda Alexander of the Central Office Stormwater Unit at [phone], ext. 584
Sincerely,
Bradley Bennett, Supervisor
Stormwater and General Permits Unit
cc: Central Files
Stormwater and General Permits Unit Files
Asheville Regional Office
1617 Mail Service Center, Raleigh, North Carolina 27699-1617 Telephone [phone] FAX [phone]
An Equal Opportunity Affirmative Action Employer 50% recycled/ 10% post -consumer paper

State of North Carolina
Department of Environment,
Health and Natural Resources
Division of Water Quality
James B. Hunt, Jr., Governor
Wayne McDevitt, Secretary
A. Preston Howard, Jr., P.E., Director
Thomas Z. Guthrie
Shuford Mills, Inc.
P.O. Box 2228
Hickory, NC 28601
Dear Permittee:
e��
IDEHNR
July 24, 1997
Subject: Certificate of Coverage No. NCG500321
Renewal of General Permit
Dudley Shoals Plant
Caldwell County
In accordance with your application for renewal of the subject Certificate of Coverage, the Division is forwarding
the enclosed General Permit. This renewal is valid until July 31, 2002. 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 December 6,1983. If any parts, measurement
frequencies or sampling requirements contained in this permit are unacceptable to you, you have the right to request
an individual permit by submitting an individual permit application. Unless such demand is made, this certificate
of coverage shall be final and binding.
The Certificate of Coverage for your facility is not transferable except after notice to the Division. Use the enclosed
Permit Name/Ownership Change form to notify the Division if you sell or otherwise transfer ownership of the
subject facility. The Division may require modification or revocation and reissuance of the Certificate of Coverage.
If your facility ceases discharge of wastewater before the expiration date of this permit, contact the Regional
Office listed below at [phone]. Once discharge from your facility has ceased, this permit may be rescinded.
This permit does not affect the legal requirements to obtain other permits which may be required by the Division of
Water Quality, the Division of Land Resources, 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 the NPDES Group at the address below.
Sincerely,
A. Preston Howard,
cr. Central Files
Asheville Regional Office
NPDES File
Facility Assessment Unit
P.O. Box 29535, Raleigh, North Carolina 27626-0535 [phone] FAX [phone] p&[e-mail]
An Equal Opportunity Affirmative Action Employer 50% recycled / 10% post -consumer paper

STATE OF NORTH CAROLINA
DEPARTMENT OF ENVIRONMENT, HEALTH, AND NATURAL RESOURCES
DIVISION OF WATER QUALITY*
GENERAL PERMIT NO. NCG500000
CERTIFICATE OF COVERAGE NO. NCG500321
TO DISCHARGE NON -CONTACT COOLING WATER, COOLING TOWER AND BOILER
BLOWDOWN, CONDENSATE, EXEMPT STORMWATER, COOLING WATERS ASSOCIATED WITH
HYDROELECTRIC OPERATIONS, AND SIMILIAR WASTEWATERS 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,
Shuford Mills, Inc.
is hereby authorized to discharge
cooling tower blowdown and other similar wastewaters
from a facility located at
Dudley Shoals Plant
NCSR 1749 (Burns Road)
Dudley Shoals
Caldwell County
to receiving waters designated as subbasin 30832 in the Catawba River Basin
in accordance with the effluent limitations, monitoring requirements, and other conditions set forth
in Parts I, II, III and IV of General Permit No. NCG500000 as attached.
This certificate of coverage shall become effective August 1, 1997.
This certificate of coverage shall remain in effect for the duration of the General Permit.
Signed this day July 24,1997.
T�
A. Preston Howard, Jr., P.E., Director
Division of Water Quality
By Authority of the Environmental Management Commission

Letter to THOMAS Z. GUTHRIE April 15, 1997
NCG500321 �5
INVOICE FOR RENEWAL OF 0
NPDES PERMIT Qd
Check here if you do NOT wish to renew this permit.
Please return this page along with a letter documenting your reasons
for not requesting renewal to:
Mr. Charles H. Weaver, Jr.
Division of Water Quality/WQ Section
NPDES Group
Post Office Box 29535
Raleigh, North Carolina 27626-0535
Check here if you wish to renew this permit.
Please verify that the following information is documented accurately:
Mailing Address ,�/
THOMAS Z. GUTHRIE I� No revision required.
SHUFORD MILLS - DUDLEY SHOALS PL "'`"'iiit---'"'"_'
P.O. BOX Revision required. (Please specify below.)
28
HICKORY,, NC 28601 N
Phone number: 4204}� rlo(�3U-2,t 3
Fax number: Iaf--A28'1S31S
e-mail address:
Facility Location
THOMAS Z. GUTHRIE
SHUFORD MILLS - DUDLEY SHOALS PL
NCSR 1749 (BURNS ROAD)
DUDLEY SHOALS, NC 28630
,,WNo revision required.
Revision required. (Please specify below.)
Please retum(this page with your letter requesting renewal, and $400 fee (payable to NCDEHNR) to:
Mr. Charles H. Weaver, Jr.
Division of Water Quality/WQ Section
NPDES Group
Post Office Box 29535
Raleigh, North Carolina 27626-0535
Signature of applicant or authorized representative
Date
q! 2 j

r 41-r-
m SENDER/
'o •Complete Items 1 and/or 2 for additional services.
m INConriplete
items 3, 4a, and 4b.
• Prim your name and address on the reverse of this torn so that we can return this
card to you.
•Attach this form to the front of the mailpiece, or on the back it space does not
Permit.
tp - • Write'Refum Receipt Requested' on the mailpiece below the article number.
•The Return Receipt will show to whom the article was delivered and the date
delivered.
0
m 3. Article
yA�djdressed to-:7
0. Ellt ttft3 L.&V
� 1L�rn�
R 2z
z
WIC
5. Received By: (Print Name)
W
g 6. Sign t n ress Agent
°a X
PS Form 3811, December1994
I also wish to receive the
following services (for an
extra fee):
1. ❑ Addressee's Address
2
2. ❑ Restricted Delivery
in
Consult postmaster for fee.
n
4b. Service Typt
❑ Registered
PL❑ Express Mail
❑ Return Receipt
and fee is
E
0
❑ Certified of
❑ Insured S
COD
✓ T
y If sted C
a m
t
F
L661 �9 ddtl

SMSHUFORD MILLS, INC.
704 326-2131 • PO BOX 2228 • HICKORY NC 28603-2228
CORPORATE
April 25, 1997
Mr. Charles H. Weaver, Jr.
Division of Water Quality/WQ Section
NPDES Group
PO Box 29535
Raleigh NC 27626-0535
Dear Mr. Weaver:
We would like to apply for renewal of NPDES Permit No.
NCG500321 for our Dudley Shoals plant located in Caldwell County.
Very truly yours,
Thomas Z. Guthrie
Vice President
TG:lz

State of North Carolina
Department of Environment,
Health and Natural Resources
Division of Water Quality
James B. Hunt, Jr., Governor
Jonathan B. Howes, Secretary
A. Preston Howard, Jr., P.E., Director
Mr. Thomas Guthrie
Shuford Mills, Inc.
P. O. Box 2228
Hickory, North Carolina 28601
Dear Mr. Guthrie:
IT
A&4
IDFEE HNFRI
July 31, 1996
Subject: Issuance of NPDES No. NCG500321
Dudley Shoals Plant
Caldwell County
In accordance with your request received April 12, 1996, we are forwarding herewith the
Certificate of Coverage for the subject facility. This Certificate of Coverage 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
December 6, 1983.
Please note that the Division has reviewed the revised biocide worksheets and has approved
the use of CW7-503 and CWT-530 are acceptable at the stated dosage rates and discharge
conditions. Please see the attached memo from the Aquatic Survey and Toxicology Unit.
If any parts, measurement frequencies or sampling requirements contained in this permit
are unacceptable to you, you have the right to request an individual permit by submitting an
individual permit application. Unless such demand is made, this certificate of coverage shall be
final and binding. Please take notice that this certificate of coverage is not transferable except after
notice to the Division of Environmental Management. The Division of Environmental Management
may require modification or revocation and reissuance of the certificate of coverage.
This permit does not affect the legal requirements to obtain other permits which may be
required by the Division of Environmental Management or permits required by the Division of
Land Resources, 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 Susan
Robson at telephone number 9191733-5083.
Sincerely,
�Idginal Signed By
A�A�!WAAAWd, Jr., P.E.
cc: Central Files
Asheville Regional Office
Mr. Roosevelt Childress, EPA
Permits and Engineering Unit
Facility Assessment Unit
P.O. Box 29535, Raleigh, North Carolina 27626-0535 Telephone [phone] FAX [phone]
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DIVISION OF WATER QUALITY
July 18, 1996
MEMORANDUM:
To: Susan Robson
Through: Matt Matthews Y'" "'_
From: Melissa Rosebrock vP
Subject: Shuford Mills -Dudley Shoals Plant (outfalls 001, 002, and 003)
Use of Biocides
NPDES No. NCG 500321
Caldwell County
.n .
Shuford Mills -Dudley Shoals Plant has resubmitted Biocide Forms 101 for approval of CWT-
503 and CWT-530. Data concerning the dosage rates of the compounds, sN.stem volumes, average daily —
discharge, toxicity of the active ingredients and/or breakdown products, degradation, and minimum
stream flow have also been reviewed and evaluated.
Please note that CW7-503 is composed of two active ingredients: 15% Disodium ethylene r
bisdithiocarbamate (NABAM) and 15% Sodium dimethyldithiocarbamate (SDDC). Toxicity and
degradation data was submitted for each of the active ingredients rather than for the product as a whole.
Since the data reported for SDDC is the most conservative, we have used those values in our —
calculations. The facility has also submitted Biocide 101 calculations for each discharge point and for
each species of test organisms listed in section III of the worksheet (rainbow trout and Daphnia magna).
Given the geographic location of the facility, the more appropriate toxicity data -would be for the rainbow
trout (15% SDDC LC50 = 2.27 mg/1). Our calculations for CWT-503 on the attached worksheets are
based upon rainbow trout toxicity and degradation values for 15% SDDC.
Calculations summarized on the accompanying worksheets predict that the use of CWT-503 and
CWT-530 at the stated dosage rates and discharge conditions will not result in toxic impact to aquatic
life in the receiving stream. Therefore, the use of these products as biocides at Shuford Mills -Dudley
Shoals Plant (outfalls 001, 002 and 003) is deemed acceptable. If there are questions regarding this
review please contact me at [phone].
Attachments
cc: Forrest Westall-ARO
Central files

STATE OF NORTH CAROL]NA
DEPARTMENT OF ENVIRONMENT, HEALTH, AND NATURAL RESOURCES
DIVISION OF WATER QUALITY
TO DISCHARGE NON -CONTACT COOLING WATER, COOLING TOWER AND BOILER BLOWDOWN,
CONDENSATE AND SIMILAR WASTEWATERS UNDER THE
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,
Shuford Mills, Inc.
is hereby authorized to discharge air wash water and coiling town blowdown from a facility located at
Dudley Shoals Plant
the junction of NCSR 1002 and NCSR 1749
Dudley Shoals
Caldwell County
to receiving waters designated as Upper Little River in the Catawba River Basin
in accordance with the effluent limitations, monitoring requirements, and other conditions set forth in Parts I, II, III
and IV of General Permit No. NCG500000 as attached.
This certificate of coverage shall become effective July 31,1996
This Certificate of Coverage shall remain in effect for the duration of the General Permit.
Signed this day July 31, 1996
Original Signed BY
Coleen H. Sullins
A. Preston Howard, Jr., P.E.,Director
Division of Water Quality
By Authority of the Environmental Management Commission

Qp'�ni
0 0_�
DDi
oant
po7
n
15
D
17/ �✓
N II
ROAD CLASSIFICATION
PRIMARY HIGHWAY LIGHT -DUTY ROAD, HARD OR
HARD SURFACE IMPROVED SURFACE
SECONDARY HIGHWAY
HARD SURFACE C001r= UNIMPROVED ROAD
Latitude:35051'51" Longitude:81022'27"
Map # D17SW Sub -basin 03-08-32
Stream Class WS IV
Discharge Class Industrial
Receiving Stream Upper Little River
Permit exp. 07/31/97 Qw
It 10
M�.�IM \ J /r(i�`-� ,
1
SCALE 1:24 000
0 1 MILE
0 7000 FEET
.. ..
1 0 1 KILOMETER
CONTOUR INTERVAL 10 FEET
QUAD LOCATION NCG500321
Caldwell County
Shuford Mills, Inc.

SOC PRIORITY PROJECT: No
TO: PERMITS AND ENGINEERING UNIT
WATER QUALITY SECTION
ATTENTION: Susan Robson
DATE: May 20, 1996
NPDES STAFF REPORT AND RECOMMENDATION
COUNTY Caldwell
PERMIT NUMBER NCG500321
PART I - GENERAL INFORMATION
1. Facility and Address: Shuford Mills, Inc - Dudley Shoals Plant
Post Office Drawer 2228
Hickory, N. C. 28603
2. Date of Investigation: March 22, 1996
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3. Report Prepared By: James R. Reid �PPPn( - �4-Je
4. Persons Contacted and Telephone Number: Cecil Klein
704-396-3371 -
S. Directions to Site: Shuford Mills is located in the community of
Dudley Shoals in Southeastern Caldwell County at the junction of SR 1002
(Dudley Shoals Road) and SR 1749.
6. Discharge Point(s), List for all discharge points:
Latitude: Longitude:
Point A 350 51' 51" 810 22' 27"
Point B 350 51' 4811 810 22' 2811
Point C 350 5111 55" 810 22' 28"
Attach a USGS map extract and indicate treatment facility site and discharge
point on map.
U.S.G.S. Quad No. D13SE U.S.G.S. Quad Name Bethlehem
7. Site size and expansion area consistent with application? _X Yes
8. Topography (relationship to flood plain included): Hilly, slopes to 30%.
9. Location of nearest dwelling: Approximately 300 feet.
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10. Receiving stream or affected surface waters: Upper Little River
a. Classification: WS-IV
b. River Basin and Subbasin No.: Catawba 030832
C. Describe receiving stream features and pertinent downstream uses:
Rocky bottom, wooded banks, deep pools separated by shoals. Downstream.
uses include fishing, wading, fish and wildlife propagation.
PART II - DESCRIPTION OF DISCHARGE AND TREATMENT WORKS
1. a. Type of wastewater to be permitted 0.00132 MGD (Ultimate Design
Capacity)
b. What is the current permitted capacity of the Wastewater Treatment
Facility? New facility
C. Actual treatment capacity of the current facility (current dosing
capacity) 0.00132 MGD
d. Date (a) and construction activities allowed by previous Authorization
to Construct issued in the previous two years: None
e. Description of existing or substantially constructed wastewater
treatment facilities: Discharge of air wash and cooling tower
blowdown
f. Description of proposed wastewater treatment facilities: No treatment
facilities are proposed
g. Possible toxic impacts to surface waters: None known or anticipated
h. Pretreatment Program (POTWs only): n/a
in development approved
should be required not needed
2. Residuals handling and disposal scheme: N/A
a. If residuals are being land applied, please specify
DEM Permit Number
Residuals Contractor
Telephone number
b. Residuals stabilization:" PSRP PFRP OTHER
C. Land fill:
d. Other disposal/utilization scheme (Specify):
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3. Treatment plant classification: Less than 5 points; no rating (include
rating sheet, if appropriate). N/A
4. SIC Codes (s) : 228
Wastewater Code(s): Primary 17 Secondary
MTU Code: 0000
PART III - OTHER PERTINENT INFORMATION
1. Is this facility being constructed with Construction Grant funds (municipals
only) ? no
2. Special monitoring requests:
3. Important SOC< JOC, or compliance schedule dates: (indicate)
Date
Submission of Plans and Specifications
Begin construction
Complete Construction
4. Alternative Analysis Evaluation
Spray Irrigation"
connection to Regional Sewer System:
Subsurface:
Other disposal options:
5. Other Special Items:
PART IV - EVALUATION AND RECOMMENDATIONS
Issue Certificate of Coverage for Shuford Mills, discharges of air washer
wastewater and cooling tower blowdowri.
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ature of eport Preparer
r
ater Quality Regional Supervisor
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