NC0001643_Waste Load Allocation_19960919

7
NPDES WASTE LOAD ALLOCATION
PERMIT NO.: NC0001643 Modeler ,Date Rec. #
PERMITTEE NAME:
Fieldcrest Cannon, Inc. - `r a i��� S i
FACILITY NAME: New Street Wastewater Treatment Plant
Facility Status: Existing
Permit Status: Renewal
Major Minor
Pipe No.: 001 Drainage Area(mi2): 1,740 Average Streamflow(cfs): 1,653
Design Capacity: 0.50 MGD s7Q10 (cfs): 370 w7Q10 (cfs): 610 30Q2 (cfs): 740
Domestic(% of Flow): 9 % Toxicity Limits: Acute(Fathead Minnow 24 hr.) P/F 21 %
February, May, August, and November
Industrial (% of Flow): 91 %
Upstream Location: 50' to 100' above outfall
Comments: Downstream Location: Highway 700
Parameters: temperature, dissolved oxygen, pH,
conductivity
Special instream monitoring locations or monitoring frequencies:
RECEIVING STREAM:Dan River
Daily Maximum Monthly Average
Class: C Wasteflow(MGD): 0.500
Sub-Basin: 03-02-03 BODS (#/d): 39.2 19.6
Dissolved Oxygen (mg/I): monitor
Reference USGS Quad: B 20 NW (please attach) TSS (#/d): 39.2 19.6
pCounty: Rockingham ( : 6-9
#
COD (#/d): 78.4 39.2
Copper WA): monitor monitor
Regional Office: Winston-Salem Regional Office Temperature (°C): monitor monitor
Previous Exp. Date: 2/28/97 Treatment Plant Class: II Total Phosphorus (mg/I): monitor monitor
Total Nitrogen (mg/I): monitor monitor
Classification changes within three miles:
Index#22- (39) 9/1/57 No changes There shall be no discharge of floating solids or visible foam in other
than trace amounts.
Requested by: 1,,4 Cabe Date: 9/18/96 n-irri7711)Prepared by: ,- - ,ez Date: 1 DI
I 0 4:*
Reviewed by: OPAMIEr =% Date:
w . L-e-1 v.os r„ /sz

FACT SHEET FOR WASTELOAD ALLOCATION RECEIVED
N.C. Dept. of EHNFt
Request# 8514
• Facility Name: Fieldcrest Cannon,Inc - New Street Waste Water TreattliNntrfin1996
NPDES No.: NC0001643
Type of Waste: Industrial-91% Domestic -9% Wi n sto n-r a I e r
Facility Status: Existing i o n u f Office
Permit Status: Renewal Stream Characteist
Receiving Stream: Dan River USGS #
Stream Classification: C Date: 1996 update
Subbasin: 03-02-03 Drainage Area(mi2): 1,740
County: Rockingham Summer 7Q10 (cfs): 370
Regional Office: Winston - Salem Winter 7Q10(cfs): 610
Requestor: Cabe Average Flow (cfs): 1,653
Date of Request: 9 / 18 / 9 6 30Q2 (cfs): 740
Topo Quad: B 20 NW IWC(%): 0.21 %
Wasteload Allocation Summary
Sulfide, (as a sulfide dye) has no State or Federal standard. The criterion currently used is based
upon EPA studies using a soluble species of sulfide. Dye sulfides produced from textile processes
are only slightly soluble. Therefore,review and analysis for this parameter was very conservative
as the soluble sulfide criterion's were applied. Three other important factors involved in the
potential toxicity of sulfide, (i.e. the formation of hydrogen sulfide) were pH, temperature, and,0
dissolved oxygen. Both effluent and instream data indicated that pH was generally in the 7.0
range, therefore only about 50% of the soluble sulfide in the effluent would be available for the 7
production of hydrogen sulfide, (taken from EPA study findings). Temperatures were normal for'
this area and dissolved oxygen levels rarely dipped below 7.0 mg/1 instream, (from 1995 instream
data). Hence, the possible formation of hydrogen sulfide has a very low potential.
This finding, coupled with the consistent passing on the toxicity test, the low IWC, and the
changes in processes in the plant which no longer use sulfidcdyes leads to a recommendation that --3
monitoring of tris parameter be droppeTirom the permit. Request Region input.,/,,.‘- Q‘'` CA)
-
Facility included an "Engineering Alternatives Analysis" in the application for this permit renewal. ,_
As part of this two page overview, connection to the City of Eden WWTP was discounted as an
option. This was based upon the City of Eden being under a consent order, (which expired in
1992) and upon increased costs involved in meeting POTW pretreatment standards. The City of
Eden already receives one discharge from a Fieldcrest.Cannon plant and does have the capacity to
take on this plant with little to no pretreatment requirements. Connection to the City of Eden may
require a pump station, but that is not known for sure at this time.
It is requested that another, (more complete)Engineering Alternatives Analysis be performed for
issuance of this permit.
Special Sc edule equirements and additional comments from Reviewers:
44,_ JT /1 -_< �(' ....-a ,---)--,z-=--5 A a. 0 c
Recommended by: Date: zZ oar c, 1176,
Farr611 eough
Instream Assessment: C?itk1L >(. 4vZ ,&1YY-' Date: /D '')L/I l(,
Regional Supervisor: -5 / Date: /b " Z7-CG
Permits&Engineering: / ze 171
4,.
4
,. Date: / (i 6
(&
;41)V 2 2, 96 tow gr)
RETURN TO TECHNICAL SERVICES BY:

t
TOXICITY TEST
Type of Toxicity Test: Acute Toxicty (Fathead Minnow 24 hr.) P/F
Existing Limit: 25%
Recommended Limit: 21%
Monitoring Schedule: February,May. August, and November
TOXICS/METALS/CONVENTIONAL PARAMETERS
Existing Limits Daily Maximum Monthly Average
Wasteflow (mgd): 0.500 (continuous)
BODS(#/d): 160.6 80.3 (weekly)
Dissolved Oxygen (mg/1): monitor (weekly)
TSS (#/d): 160.6 80.3 (weekly)
pH (SU): 6-9 (weekly)
COD(#/d): 321 160.6 (weekly)
Chromium(µg/1): monitor monitor (monthly)
Copper(4/1): monitor monitor (monthly)
Sulfide(µg/1): monitor monitor (Qrtly)
Temperature (°C): monitor monitor (weekly)
Total Phosphorus (mg/1): monitor monitor (Qrtly)
Total Nitrogen(mg/1): monitor monitor (Qrtly)
Recommended Limits Daily Maximum Monthly Average
Wasteflow(mgd): 0.500 (continuous)
BODS(#/d): 39.2 * 19.6 * (weekly)
Dissolved Oxygen(mg/1): monitor (weekly)
TSS (#/d): 39.2 * 19.6 * (weekly)
pH (SU): 6- 9 (weekly)
COD(#/d): 78.4 * 39.2 * (weekly)
Chromium(14/1): not required
Copper(4/1): monitor monitor (monthly)
Sulfide (µg/1): not required (refer cover page)
Temperature(°C): monitor monitor (weekly)
Total Phosphorus (mg/1): monitor monitor (Qrtly)
Total Nitrogen(mg/1): monitor monitor (Qrtly)
* Facility sold blanket manufacturing process and will dismantle facility in near future,
(approximately 2 months). Production flows for this facility will be substantially decreased,
therefore recommended limits will also decreased. Current DMR's included blanket
manufacturing production, thus review of these seems to indicate that facility would not be able
to meet these newly recommended limits. Please note this when reviewing Fact Sheet.
Parameter(s) are water quality limited. For some parameters, the available load capacity of
the immediate receiving water will be consumed. This may affect future water quality based
effluent limitations for additional dischargers within this portion of the watershed.
OR
_x_ No parameters are water quality limited, but this discharge may affect future allocations.

r
I .
Chromium: Max.Pred Cw 0.0 18 out of 18 samples below detection of 0.05 mg/1
Allowable Cw 20.3
Copper: Max.Pred Cw 0.3 13 out 18 samples above a detection level of 0.05 mg/1
Allowable Cw 2.8 maximum value of 0.14 mg/1 in October, 1995
Sulfide: Max.Pred Cw 32.3 2 out of 5 samples above detection of 0.10 mg/1
Allowable Cw n/a maximum value of 1.45 mg/lin January, 1995
slightly soluble dye product- no State or Federal Standard
INSTREAM MONITORING REQUIREMENTS
Upstream Location: 50' to 100' above outfall
Downstream Location: Highway 700
Parameters: temperature,dissolved oxygen,pH,conductivity
This area of the Dan River is ideal for the formation of an association of dischargers to perform instream
monitoring. Request Region comment as to whether this and other facilities in area would be interested in
forming such an association.
MISCELLANEOUS INFORMATION&SPECIAL CONDITIONS
Adequacy of Existing Treatment
Has the facility demonstrat4the ability to meet the proposed new limits with existing
treatment facilities? Yes ' No
If no,which parameters cannot be met?
Would a "phasing in"of the new limits be appropriate?Yes No
If yes,please provide a schedule(and basis for that schedule)with the
regional office recommendations:
If no, why not?
Special Instructions or Conditions
Wasteload sent to EPA? (Major) (Y or N)
(If yes, then attach schematic,toxics spreadsheet,copy of model,or,if not modeled,
then old assumptions that were made,and description of how it fits into basinwide
plan)
Additional Information attached? (Y or N) If yes,explain with attachments.

I.
Facility Name Fieldcrest Cannon, Inc Permit# NC0001643 Pipe# 001
ACUTE TOXICITY PASS/FAIL PERMIT LIMIT (QRTRLY)
The permittee shall conduct acute toxicity tests on a quarterly basis using protocols defined
in the North Carolina Procedure Document entitled "Pass/Fail Methodology For
Determining Acute Toxicity In A Single Effluent Concentration." The monitoring shall be
performed as a Fathead Minnow (Pimephales promelas) 24 hour static test, using effluent
collected as a 24 hour composite. The effluent concentration at which there may be at no
time significant acute mortality is 90 % (defined as treatment two in the North Carolina
procedure document). Effluent samples for self-monitoring purposes must be obtained
during representative effluent discharge below all waste treatment. The first test will be
performed after thirty days from the effective date of this permit during the months of
February, May, August, and November.
All toxicity testing results required as part of this permit condition will be entered on the
Effluent Discharge Monitoring Form (MR-1) for the month in which it was performed,
using the parameter code TGE6C. Additionally,DEM Form AT-2(original)is to be sent to
the following address:
Attention: Environmental Sciences Branch
North Carolina Division of
Environmental Management
4401 Reedy Creek Road
Raleigh, N.C. 27607
Test data shall be complete and accurate and include all supporting chemical/physical
measurements performed in association with the toxicity tests, as well as all dose/response
data. Total residual chlorine of the effluent toxicity sample must be measured and reported
if chlorine is employed for disinfection of the waste stream.
Should any single quarterly monitoring indicate a failure to meet specified limits, then
monthly monitoring will begin immediately until such time that a single test is passed.
Upon passing,this monthly test requirement will revert to quarterly in the months specified
above.
Should any test data from either these monitoring requirements or tests performed by the
North Carolina Division of Environmental Management 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 and appropriate environmental controls, shall
constitute an invalid test and will require immediate retesting(within 30 days of initial
monitoring event). Failure to submit suitable test results will constitute noncompliance
with monitoring requirements.
7Q10 370 cfs
Permitted Flow 0.500 MGD Recommended by:
IWC 0.21
Basin & Sub-basin 03-02-03
Receiving Stream Dan River Farrell Keo :h
County Rockingham Date zz oave.s tea
QAL PIF Fathead 24 Version 9/91

Request# 8514
. Facility Name: Fieldcrest Cannon, Inc-New Street Wastewater Treatment Plant
_ NPDES No.: NC0001643
Type of Waste: 9% Domestic 91 % Industrial
Facility Status: Existing
Permit Status: Renewal stream Characteristic:
Receiving Stream: Dan River USGS#
Stream Classification: C Date: previous WLA 1996
Subbasin: 03-02-03 Drainage Area(mi2): 1,706 1,740
County: Rockingham Summer 7010(cfs): 314 370
Regional Office: Winston-Salem Winter 7010(cfs): 580 610
ReDate of Request: 9/estor: 18/96 e 4 Average(cf Flow(cfs): 740
1,621 1,653
Topo Quad: B 20 NW IWC(%): 0.25% 0.21 %
1982: modeled,but not apparent whether other dischargers in area included. Limits based upon 40 CFR 410.32 and 410.42
1988: reissued with new modeling analysis. Limits based upon increased production coupled with more stringent CFR limits,
therefore the two tended to equal each other out. Addition toxicity test and instream monitoring.
1993: reissued w/decrease in production. No fabric finishing was being done at this facility, (it had been done in the past),therefore
sulfide monitoring was changed to quarterly and phenols monitoring was dropped. APAM requirement was also dropped.
Color had been an ongoing issue in this area and numerous letters and memo's exist in file about it.
Toxicity Test
passing since 1992
Instream Date
no violations-generally above 7.0 mg/I(attached)
Sulfide
Attached is a fax from EPA regarding sulfide toxicity. A number of issues need to be addressed regarding this study:
• First,the paper focuses on the most toxic of the compounds which could form from sulfides in the effluent;hydrogen sulfide.
Unfortunately,to achieve this compound formation,the sulfide needs to be soluble. Both the Hawley's Condensed Chemical
Dictionary, 12th ed., Richard J. Lewis,Sr.and Chemistry,2nd ed.,Steven S.Zumdahl note that sulfide dyes are only slightly
soluble, (or not soluble).
• The second aspect is that pH is a strong influence as to the amount of effluent sulfide which can combine to form hydrogen sulfide.
In other words,at a pH of 7.0,(which is the general range of pH for both the effluent and instream)approximately 50%of the
effluent concentration can form into hydrogen sulfide.
• It was also stated that in well-aerated water, H2S is oxidized back into sulfates and hydrogen, (which often discounts its possible
toxicity).
• These factors are addressed further in the latter sections of this paper,but generally the lowest numbers for toxicity are determined
via laboratory procedures using juveniles and eggs and fry for species not existing in this waterbody.
• Finally, no standard exits for sulfides for either the State or Federal government.
• Also, it should be noted that fish are sensitive to hydrogen sulfide and will leave the area given an escape route,(which should
easily exist considering this discharge has a 0.25% IWC). Finally,this facility has a consistent record of passing its toxicity and the
processes requiring sulfide dyes are not used,(and haven't been used here since the last WLA in 1993).
To view the data for this parameter I chose to use the 0.3-0.4 mg/I concentration and doubled*it since only about 50%of the effluent
sulfide would be soluble for the 7.0 pH at this facility-note that I assumed that this effluent sulfide was soluble to keep a conservative
focus upon this parameter. Using this number,the allowable effluent concentration would be 334.9 mg/I and the maximum predicted
concentration, (using only 5 samples available for analysis)would be 32.3 mg/I which is not within one-tenth of the allowable.
Therefore,considering the conservative nature of this allowable level, it seems justifiable to drop the monitoring requirement.
since 2 for the price of one is the same as 50%off, I doubled the allowable rather than cut the effluent data in half,(which had the
potential of throwing the statistics off).
Flows previous 1996
Chromium: Max. Pred Cw 0.0 0.0 18 out of 18 samples below detection of 0.05 mg/I
Allowable Cw 23.9 20.3
Copper: Max. Pred Cw 0.3 0.3 13 out 18 samples above a detection level of 0.05 mg/I
Allowable Cw 3.3 2.8 maximum value of 0.14 mg/I in October, 1995
Sulfide: Max. Pred Cw 32.3 32.3 2 out of 5 samples above detection of 0.10 mg/I
Allowable Cw n/a n/a maximum value of 1.45 mg/I in January, 1995
slightly soluble dye product-no State or Federal Standard

Page 1
Note for Farrell Keough
From: Mary Cabe
Date: Oct 11, 1996 3:41 PM
Subject: RE: fieldcrest canon
To: Farrell Keough
Battle Moore, [phone], says that 28000 lbs of comforters are produced/day, and that
the blanket manufacturing has been sold. Therefore,their flow will be 74,000 GPD.
40 CFR 410.32
Max/day Avg/month Allowable Allowable
(lb/Klb) (lb/Klb) Max/day(lb) Avg/month(lb)
BODS 1.4 0.7 39.2 19.6
COD 2.8 1.4 78.4 39.2
TSS 1.4 0.7 39.2 19.6
From: Farrell Keough on Mon, Oct 7, 1996 2:43 PM
Subject:fieldcrest canon
To: Mary Cabe
did you get the process flows info from them?
4 I o. 3 Z Mf
Boo . Y ."7
Cop I-Li
135

•
Schematic of Water Flow . • .
CITY •,14
84,000 GPD WATER 4.r. 86,000 GPD
ri
28,00o lbs C� �3.� ,;�i.��:; e�1� 56"���nn`� ��C3aS ?UK
win
1
• • Nr-I•.i€, NU 0p UK- Z Nom
P e,od vc*,a
DECORATIVE E BLANKET
BEDDING I MANUFACTURING
g� :.n WHIM
h.
SII.HIR:mss. iI ..
r
EVAPORATION
5,003 GPD +I
NON PROCESS NON
CONTACT SANITARY SANITAR CONTACT
BOILER COOLING USE WATER USE COOLING BOILER —
TOWER (SLASHING) TOWER
4,000 GPD 54,800 GPD 15,200 GPD 7,000 GPD 6,0 i'GPD 56,000 GPD 4,030 GPD
1 1 Jr l - 1
EVAPORATION/STEAM EVAPORATION EVAPORATION EVAPORATION/STE
8000 GPD 2000 GPD 3,000 GPD 5,000 GPD
WASTEWATER
74,000 GP 9 TREATMENT 4 73,000 GPD
PLANT •
T 1 T 1
FIELDCREST MILLS, INC.
NEW RN�(t/001 EDEN, NORTH CAROLINA
•
PD
TITLE 0 Street ,wwTP
pow s chew1o.-PL -
DRAWN IIT DATE) - s-y6134{1lc Amen- '15 '

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04%19.'93 14:_2 (1C-,TEF L1ANASEMIEi4T REG IOH IV -, 919 733 9919 NO.572 D02
SULFIDE - HYDROGEN SUE
CRITERION:
2 ug/L undissociated H2S for
fish and other aquatic life, fresh
and marine water.
INTRODUCTION:
Hydrogen sulfide is a soluble, highly poisonous, gaseous
compound having the characteristic odor of rotten eggs. It is
detectable in air by humans at a dilution of 0.002 ppm. It will
dissolve in water at 4 , 000 ng/L at 20° C and one atmosphere of
pressure. Hydrogen sulfide biologically is an active compound
that is found primarily as an anaerobic degradation product of
both organic sulfur compounds and inorganic sulfates. Sulfides
are constituents of many industrial wastes such as those from
tanneries, paper mills, chemical plants, and gas works. The
anaerobic decomposition of sewage, sludge beds, algae, and other
naturally deposited organic material is a major source of
Ha.ilcv-s cdN1io.N,5.04 ci.�Mtcnll�,cTroNIDRK' IZ `wel-, R•clAado,jv
Tot Su1Fldc dC3 ARE a¢C. oNltz
hydrogen sulfide. MUt�• z� d., 3+ vc v s. �vMdakl j1O te l/y,
aoltkk.
when soluble sulfide are added to water they react with
6,AW hydrogen ions to form ,his or H2S, ) the proportion of each depending
t J
„6,.-0`N-On the pH. The toxicity of sulfides derives primarily from H2S
' ' ) ions.
Aorather than from the hydrosul f ids (HS-) or sulfide (5=
When hydrogen sulfide dissolves in water it dissociates according
to the reactions:
H2S HS_ + H+ and HS_ Sa + H�
' 0Nw`
ear At pH 9 about 99 percent of the sulfide is in the form of HS_
roo
,`rt
PHat pH 7 the sulfide is equally divided between HS_ and,H2S= and
1- at pH 5 about 99 percent of the sulfide is present as H2S (NAS
CN s°l°
1 v

• . 04 1 -93 :27 1,11:TEP t1ANAGEI ENT REG 1 J I U i 919 733 9919 NC.572 17213
1974) . The fact that H2S is oxidized in well-aerated water r. .
D0.5 POO
by natural biological systems to sulfates or is biologically { ,row
et
oxidized to elemental sulfur has caused investigators to minimize P° eAg.l•iv 70 '
the toxic effects of H2S on fish and other aquatic life. C`."'e'"'a s""'"`Tz_
roitA c� 7
RATIONALE:
The degree of hazard exhibited by sulfide to aquatic animal
-WcOG cm-tit-WV,
life is dependent on the temperature, pH, and dissolved oxygen. doNot
At lower pH values agreater proportion is in the form of the > �_ a"� R�
P P AeA_
toxic undisseciated H2S. In winter when the pH is neutral or
below or when dissolved oxygen levels are low but not lethal to
fish, the hazard from sulfides is exacerbated. Fish exhibit a
strong avoidance reaction to sulfide. Based on data from
experiments with the stickleback, Jones (1964) hypothesized that
if fish encounter a lethal concentration of sulfide there is a
reasonable chance they will be repelled by it before they are
harmed. This, of course, assumes that an escape route is open.
Many past data on the toxicity of hydrogen sulfide to fish
and other aquatic life have been based on extremely short
exposure periods. Consequently, these early data have indicated
that concentrations between 0.3 and 0.4 mg/L permit fish to
survive (Van Horn 1958, Boon and Follis 1967, Theede et al. ,
1969) . Recent : ong-term data, both in field situations and under
controlled laboratory conditions, demonstrate hydrogen sulfide
toxicity at lower concentrations.
Colby and Smith' (1967) found that concentrations as high as '.
0.7 mg/L have been found within 20 mm of the bottom of sludge
beds, and the levels of 0.1 to 0.02 mg/L were common within the
•
•

04/19/93 14:24 WATER t14Jr-C,EIEtJT REGION IV - 919 733 9919 NO.572 D04
first 20 nm of water above this layer. walleye (Stizoet,,,edion _ •
vitreur..) eggs held in trays in this zone did not hatch. Adelman •
and Smith (1970) reported that the hatchability of northern pike
(Esox lucius) eggs was substantially reduced at 25 ug/L H2S; at
47 ug/L mortality was almost complete. Northern pike fry had 96
hour LC50 values that varied from 17 to 32 ug/L at normal oxygen
levels of 6.0 mg/L. The highest concentration of hydrogen
sulfide that had no observable effect on eggs and fry was 14 and
4 ug/L, respectively. Smith and Oseid (1972) , working on eggs,
fry and juveniles of walleyes and white suckers (Catostomus
commersoni) and Smith (1971) , Safe levels in working on walleyes
and fathead minnows, Pimephales promelas, were found to vary from
2.9 ug/L to 12 ug/L with eggs 'being the least sensitive and
juveniles being the most sensitive in short-term tests. In 96-
hour bioassays, fathead minnows and goldfish, Carassius auratua,
varied greatly in tolerance to hydrogen sulfide with changes in
temperature. They were more tolerant at low temperatures (6 to
loo C) . Holland, et al. (1960) reported that 1.0 mg/L sulfide
caused 100 percent mortality in 72 hours with Pacific salmon.
On the basis of chronic tests evaluating growth and survival, ta
the safe H2S level for bluegill (Lepomis macrochirus) juveniles
and adults was 2 ug/L. Egg deposition in bluegills was reduced
after 46 days in 1.4 ug/L H2S (Smith and Oseid, 1974) . White
•
•
sucker eggs were hatched at 15 ug/L, but juveniles showed growth
reductions at 1 ug/L. Safe level for fathead minnows were
between 2 and 3 ug/L. Studies showed that safe levels for
Gammarus Pseudolimnaeus and Hexagenia limbata were 2 and 15 ug/L,
respectively (Oseid and Smith, 1974a, 1974b) . Some species

• C1.4/19,'93 14:24 LATER 114-AGEP'ENT REGION I V 919 733 9919 NO.572 D35
•
typical of normally stressed habitats, Asellus spp., were much ,�
more resistant (Oseid and Smith, 1974c).
Sulfide criteria for domestic or livestock use have not
been established because the unpleasant odor and taste would
preclude such use at hazardous concentrations.
It is recognized that the hazard from hydrogen sulfide to
aquatic life is often localized and transient. Available data
indicate that water containing concentrations of 2.0 ug/L
undissociated H2S would not be hazardous to most fish and other
aquatic wildlife, but concentrations in excess of 2.0 ug/L would
constitute a long-term hazard.
(QUPB-263943
SEEhAPPENDIXTCRFORFMETHODOLOGYULX 1976)

1 WHOLE EFFLUENT TOXICITY TESTING O(SELF-MONITORING SUMMARY] Thu.Sep 19.1996
FA(11�'TTY REly IREMENF YEAR JAN FIB MAR APR MAY JUN 1111, AUG SEP OCT . , a •.'NOV DECDEC�� -
Fieldcrest Mule-EJesPERM(New SIJ M 211111 PIF AC LDA:90%FTIID 82 - Paull - - Pass! - - Pasty - PaidNC0001643/001 Begia:3/1194 Fmqueary:Q A Feb May Aug Nov NasCoap:SINGIE 83 - Pass - - NH/Paull Paul PPaul -- - -
Pasal
County:Rocbgham Regina:WSRO Subbuia:R0A03 94 - Paul - - Paul - - Pass, - - Paul -
PF:0.500 Special 06 - Pasts - - Paul - - HRIPua !A
7Q1O 314.0 1WC(%):0.246 Oder. 96 - Pau - - Pass - -
Fieldcrest MIlls-Salkhury-163 PERM 43118 LC50 AC LOM:649E V 92 - s90' - - >100• - - 70.71' - - >100' --
NC0005467/001 Begia:Wl/94 Finpewcy:Q A Feb May Aug Nov NoaComp:SNG E 93 - 100' - - 63.73' 69.01• - 70.71• - - 70.71' -
Coaaty:Rowsa Regina:MRO Subbasic YAU04 9s - 12.2r - - 61.24' 70.71' - 66.W - 72.62'
PP:415 Special 96 - 70.34' - - 59.13' 37.36 77.62 61.24 HR
1Q10:1030 IWC(%1:0.64 Order 96 37.35 65.8 - - 49.16 Lam 20.31
Flu On Aad Chem Cs-Sehaa PERM:2411R IC50 AC MONIT EPIS vim(GRAB) 92 - - - - - - -
NC00272271001 Begin:7/1/93 Frequency:5OWD/A NoaCoup: 93 - - - - - - - - - --
- H
u
Cowley:lo les Regia:RRO Ssbbaais:N 1J02 94 H H H H H - - - - - -
1Q EPISOD S 90 - - - - - - - -
7Qlo:o.o Iw (9�
cr.loo.o Order
FMC Corporation/ Lithium Div. PERM 2411R PIF AC LIM:90%CERIO OR DAPI I 92 - H H H H H H H H H Pass -
NC0005169/001 Begis:12/1/93 F eq ency Q A Feb May Aug Nov NonConp:SNUIE 93 - Pass - - Pass - - H H H H H
Coanty:Gamos Regius:MRO Subbasia:CB36 94 Pau' Pass' - - H H H Pass' - - H Pass'
PF:4.50 Special 95 - Paul - - H Pass Pass Pass
1Q10:0.00 IWC(%):100.00 Oder. 96 - Pass - - NM Pass -
Fsrest City WWTP Pena chr list:18% V 92 Pass - - Pass - - Pass - - Pau - --
N('0025964+001 Begin:5/I/95 Fmqueoey:Q PIP A Jan Apr Jul Oct NoaComp:Siagk 93 Pass - - Pau Pass - Pass - - - -
Pass - -
Cowty:Rmkaksd Region:ARO Subbasia:DRD02 94 Pass - - Pass Fall Pass Pass
PF:4.95 Special 9S Pus - - Pau - - Pass - - Pass
1Q10:34.8 IWC(%):11.0 Oder: 98 Pass - - Pass - - Pass
Vsr1 Bragg W WTP/NI Peine eke him:26% 92 Pass - - Pau - - Pass - - Pass - --
ClNC0003964A01 Begin:6/1/96 Frequency:Q PIF A Jan Apr Jul On No.Comp:Siagk 93 Pass - - Pass Pass - Pass - -
Counry: emberiand Region:FRO Svbbasin:CPF14 94 Fail Foil Pass Pass - - Pass(s) - Fai.Pass
PF:8.0 Special 96 Pass - - Pau - - PassPass- -
-
1Q10:35.6 IWC(%):26 Oder. 98 Pass - - Pass - - Pass
Fortran Industries/991 PERM CIIR I.IM:2.39:PERM 241IR AC LIM 109E FIII13;PF3t 92 - - - - -- - - - -
NC0062295/001 Begia:6/1/93 Fmgvewly:Q P/F A Feb May Avg Nov NoaComp:SNG1E 93 - - - - - - - H - - H -
Camay:New Ilaaover Regina:WIRO Ssbbasia:CP1,17 94 - Fa6ny.Failt Pass.PassrrM- FaWny.Passl•Fai.Pasmny Fail Fallmy.Pasal-NR.NR&am Fai,Failmy Failmy.PssiF LaM.Fakmy
PF:0.245 Special S0C:7/11/95-6/1/97 Q p/Ise await 90r%myaewM pit moan 2.3% 95 Fad.Fsany Fas.Pasall Fai.Fs6ny Fainy.Fail Pusl.Pau1 Fsilmy.3.3 3.2.Puslf - Fairnyt
1Q10:910 1W001):1.16 Order. 96 - Pasal(s)1 - - 3.3.Pasalt - -
Fraaklla Co. WASA Perm chr ling 29%;if espaad perm chr lin 49% 92 Pass - - Pass - - Pass - - Pass
-
NC0069311/001 Begin:IO/1/95 Fmw
gscy:Q PIF A Jac Apr Jul Oa NosCoap:Siagk 93 Pass - - PassPassPass -
- - Lam - Fad -
County:Frsakba Region:RRO Subbuia:TARSI 94 Fad Pass - Labs Pass - Pass - - Pass - -
PF:0.50 Special 95 Pass - - Pass - Pass Pass
1Q10:1.6 IWC(%):29 Oedtr 98 Pass - - Pass - - Pass
Franklin WWTP PERM CUR LIM:1.6% 92 - - - - - - - - Pass - - Pass
NC00215411'001 Begia:121/92 Pecqueur Q PIF A Mar Jun Sep Dec NoaCanp:SDN I.II 93 - - Pass - - Pass - - Pass - - Pus
Covey:Mama Regia:ARO Subbuin:LTNOI 94 - - Pass - - Lam Pass - Pass - - NR/Pass
PF:1.65 Special 95 - - Isle Pass - Pass Pass Pass
7Q10157 IWC(%):1.6 Onkr: 98 - - Pass - - Pus -
Fuquay-Vsrina/Ilesselk Br WWTP PIJIM CIIR LIM:9096(New perm 9/1/96) V 92 - - Fad - - Pass - - Pass - - Pass
NC00261111001 Begia:3/1/93 Fnspeeacy:Q PIE A le
Mar a Sep Dec Nu.Coreep:SINGIE 93 - - Pass - Pass - Pus - Fad
County:Wake Regina:RRO Stebbins:CP1a07 94 FM NR Pass - - Fal Pass Lata,IATE Pass Pal
PF:1.2 Special 96 Pass - Pass - - NR/Pau - - Fail Fail Pass Pass
7Q10 0.0 IWC(96):100 Order: 98 - - Pass - - Lam Fail
Furniture Illustrators, lou. Penn cMhen:90% 92 - - - - - - - - - - -
NC00947361001 Begin:2/1196 Frequency:Q PIP A las Apr Jvl Oct NoaConp:Siagle 93 - - - - - - - - - - - -
w - - - - - - - - -
PF:Comity:Randolph Region:WSRO Subbaria:YADO9 - - - - „- - -
PQ:0.001 SpecialO.Oe99 - - - - - -
7Q10 0.0 IWC(9,):100 H
O 2 oossecmive faders a'americana seacoapliaaw V Pre 1992 Data Available
IEG174D
PERM a Petit Regenerator LET=Admiaistrmive Leiser-Tarsal . Wagering= aiioring fnequeny:Q-QuanedMMoodily;y. -Mooy;BM-BimnntNy;SA-Seiniammally;A-Aamrally;OWD-Only when discharging;D-Discontinued monitoring requirement; Camden,*IS-Camaisl
•m'k'"1
B eais=hent t monthrequired 7Q10 a Receiving stream low(hew criterion(e(s) A=quarterly monitoring inteazes to mom ly upon siaglfailure Marks that lessiag must oecer-es.JAN.APR.JU1.OlT NusC omp a Canna Compli:vae Regsiteeacat
PP=Pertained flow(MGD) IWC%a Isnreata waste coecestnrwn PIN=Paulmad chruoic tee AC=Acute CI IR=Chronic
Data Notation:I-Fathead Miasow:•-Ceriodaohnia so.;nay-Mvsid shining ChV-Chromic value:P-Mortality of stared orrceatue at hilliest ecacentrariva:at-Performed by DEM Ton Evil Grouo:bt-Bad test T=ORC aignaime weird Notation:--=Data not required;NR-Not reported; Quires(1-Beginning of Qas Facility Activity Straw:1-Inactive.N-Newly Isuued(To csasuuct);II-Active but sialJirchargiag;/-Mae data available for moo h is queasier
22

January,1995 through June,1996
FaarryName= Fieldcrest Cannon,Inc Parameter=Chromium Pamm.tr=Copper [AI] Pamm.tr= Sulfide
NPDES 0= NC0001643 Standard= 0.050 mgA Standard= 0.007 mgA Standwd= MA
Ow(MOD): 0.50 mgd
7C10e(.a)= X496 uSG's 370 cis n BDL=1/2DL 111/2 DL RESULTS n BDL=1/2DL If 1/2 DL RESULTS n BDL=1/2DL If 1/2 DL RESULTS
cera(%)= FLgv.) 0.21% 1 0.025 • Std Dev. 0.0 1 0.09 Jun-96 Std Dev. 0.0 1 0.05 Std Dev. 0.6
2 0.025 • Mean 0.0 2 0.08 Mean 0.1 2 0.05 ▪ Mean 0.3
FINAL RESULTS 3 0.025 • C.V. 0.0 3 0.025 • C.V. OA 3 0.05 • C.V. 1.6
Chromium Maximum Valu. 0.0 4 0.025 • 4 0.05 4 0.14 Apr-95
Max.Pred Cw 0.0 5 0.025 • 5 0.06 5 1.45 Jan-95
Allowable Cw 23.9 a 0.025 • Muf Factor= 0.0 6 0.09 Jan-96 Mu/Factor= 2.1 6 Muff Factor= 22.3
7 0.025 • Max.Value 0.0 mg/I 7 0.09 Dec-95 Mex.Value 0.1 mg/ 7 Max.Value 1.5 mgS
Copper [Al] maximum Value 0.1 a 0.025 • Max.Pred Cw 0.0 mg/I a 0.11 Nov-95 Max.Pred Cx 0.3
mg/I a Max.Pred Cw 32.3 mgA
Mex.Pred Cw 0.3 9 0.025 • Allowable Cw 23.9 mg/ 9 0.14 Oct-95 Allowable Cw 3.3 9 Allowable Cw 0.0 man
Allowable Cw 3.3 10 0.025 • 10 0.1 10
11 0.025 • 11 0.025 1t
Sulfide Maximum Valu. 1.5 12 0.025 • 12 0.025 • 12 for-- '0 0 1-0,6/Q- 5 t wvcl Arta1,
Max.Pred Cw 32.3 13 0.025 • 13 0.025 • 13 411.«roblc l 3 33 N.9 /...€
Allowable Cw 0.0 14 0.025 • 14 0.09 May-95 14 (ger .v.1c3.,,'
15 0.025 • 15 0.08 15
16 0.025 • 16 0.025 16
17 0.025 • 17 0.07 17
18 0.025 • 18 0.09 Jan-95 18
19 19 19
20 20 20
9/24/96

January.1996 through June,1998
Facility Name- Fieldcrest Cannon,Inc Parameter=Chromium Parameter=Copper [Al] 'Par.nwbr= Sulfide
IrPDES D= NC0001643 snnd nd= 0.050 mgA Standard= 0.007 mpl @ Standeed= MA
Ow(MOD). 0.50 mgd
7010a(1449. Foam w rs 314 Cts n BDL=1/2DL It 1/2 DL RESULTS n BDL=1/2DL If 1/2 DL RESULTS n BDL=1/2DL If 1/2 DL RESULTS
11190(%)_ '''LA F1.4""1 0.25% 1 0.025 Sld Dev. 0.0 1 0.09 Jun-98 Sld Dev. 0.0 1 0.05 Std Dev. 0.6
2 0.025 • Mean 0.0 2 0.08 Mean 0.1 2 0.05 * Mean 0.3
FINAL RESULTS 3 0.025 C.V. •0.0 3 0.025 • C.V. 0.5 `. 3 0.05 C.Y. 1.8
Chromium Maximum Valu. 0.0 4 0.025 4 0.05 4 0.14 Apr-95
Max Pred Cw 0.0 5 0.025 5 0.06 5 1.45 Jan-95
Allowable Cw 20.3 6 0.025 • Mult Factor= 0.0 6 0.09 Jan-96 Mull Factor= 2.1 6 Mull Factor- 22.3
7 0.025 • Max.Value 0.0 mg/ 7 0.09 Dec-95 Max.Value 0.1 7 Max.Value 1.5 mg/
Copper [Al) Maximum Valu. 0.1 8 0.025 • Max.Pred Cw 0.0 mg/ 8 0.11 Nov-95 Max.Pred Cv 0.3 mgA4 8 Max.Pred Cw 32.3 mgA
Max.Pred Cw 0.3 9 0.025 Allowable Cw 20.3 mgA a 0.14 Oct-95 Allowable Cw 2.e mg/Pi: 9 Allowable Cw 0.0 nigh
Allowable Cw 2.1 10 0.025 10 0.1 I 10
11 0.025 it 0.025 11
Sulfide Maximum Value 1.5 12 0.025 12 0.025 12
Max.Pred Cw 32.3 13 0.025 13 0.025 • 13
Allowable Cw 0.0 14 0.025 14 0.09 May-95 14
15 0.025 15 0.08 1s
16 0.025 16 0.025 • 16
17 0.025 17 0.07 17
16 0.025 18 0.09 Jan-95 16
19 19 a 19
20 20 20
9'24/96

• Fieldcrest Cannon.Inc NC0001643
•
•
Upstream: 50'above Upstream: Highway 700
Date Temp DO Saturation pH Conduct Temp DO Saturation pH Conduct
7-Apr-95 15 9.4 93% 7.2 215 15 9.6 95% 7.1 180
12-Apr-95 14 9.4 91% 7.3 185 14 9.6 93% 7.2 150
19-Apr-95 18 9.2 97% 7.5 220 18 9.4 99% 7.3 190
28-Apr-95 18 9.0 95% 7.5 230 18 9.2 97% 7.3 205
5-May-95 16 9.4 95% 7.4 180 16 9.6 97% 7.2 150
12-May-95 20 9.0 99% 7.5 175 20 9.2 101% 7.3 150
19-May-95 18 8.8 93% 7.3 180 18 9.0 95% 7.0 160
26-May-95 23 8.5 99% 7.5 215 23 8.7 101% 7.3 190
2-Jun-95 18 8.3 88% 7.3 220 18 8.5 90% 7.2 190
9-Jun-95 23 8.2 96% 7.4 175 23 8.4 98% 7.3 160
16-Jun-95 21 8.1 91% 7.3 95 21 8.5 95% 7.2 70
23-Jun-95 24 8.0 95% 7.2 145 24 8.2 97% 7.1 130
7-Jul-95 23 8.1 94% 7.1 150 23 8.2 96% 7.2 135
14-Jul-95 26 8.0 4Yf6 7.1 175 26 8.1 twe 7.0 160
21-Jul-95 26 7.8 Aft* 7.4 180 26 7.9 4101150 7.3 160
28-Jul-95 25 7.8 19/41 7.3 165 25 7.9 iSto 7.2 149
9-Aug-95 27 7.6 49111 7.3 256 27 7.8 10140 7.2 187
16-Aug-95 27 7.5 Ain 7.2 258 27 7.7 10041 7.2 212
23-Aug-95 27 7.9 4101a 7.2 270 27 8.0 7.1 237
30-Aug-95 26 7.9 44% 7.0 221 27 8.0 SAO 7.0 182
6-Sep-95 23 7.9 92% 7.2 244 23 8.0 93% 7.1 202
13-Sep-95 23 8.0 93% 7.1 264 22 8.1 93% 7.0 229
20-Sep-95 22 8.1 93% 7.2 296 22 8.2 94% 7.1 240
Dissolved
Oxygen
10.0 -
9.5 =
9.0 -
8.5 - -
7.5
7.0 -
6.5 - Upstream
6.0 - Downstream
5.5 -
5.0 I I I t I I I I 1 I I
in u) u) u) in in in u) in in u) u)
rn °.' (3.) o) °' a) a) o) q) o) o) o)
i c�'6 > 7 , > CO > NG. NQ
a
' - k i ? ? ^ ? a ¢ Cl) Cl)
A Q) 6 a) cm CO N O) N t6 N
9/24/96

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EDEN, NORTH CAROLINA
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EDEN. NORTH CAROLINA
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Southern Photo Print& Supply Co., Greensboro, N.C.*IOOOH

ENGINEERING ALTERNATIVES ANALYSIS
NEW STREET WWTP
In considering non-discharge alternatives persuant to 15A NCAC
2H.0105 (C) (2) , the following rational is provided. Two other
options could be considered for treatment of this wastewater, one
is land application of the treated effluent and second would be
sewer connections to the local POTW.
This wastewater treatment facility was designed to treat
process wastewater from two manufacturing facilities with the plans
to build additional manufacturing in the future. The WWTP was
designed for .5 MGD. Treatment units consist of an extended
aeration activated sludge basin followed by clarification and
chlorination. The detention time of the system is several days
which minimizes sludge production, and provides a high quality
effluent for discharge to the Dan River.
Option 1 - Land Application of Treated Effluent
With a design flow of .5 MGD we would need to reserve a
minimum of 125 acres of land for an application of 20, 000
gallons/week/acre. This does not account for precipitation and
frozen ground conditions which would require more land in reserve
and additional storage. The required amount of land is not
available, and significant costs for solids storage facilities, and
engineering would be needed; therefore, this option is not
economically justifiable.
Option 2 - POTW Sewer Connections
These Fieldcrest Cannon, Inc. manufacturing facilities are
located outside the city limits of Eden. For the past several
years the City has operated the POTW under a consent order. This
has not allowed any increase in industrial wastewater contribution
to the POTW. If available, significant costs to connect to the.
sewer would be encountered, along with monthly sewer surcharge•
costs. Many POTW's are becomimg more restrictive as to
concentrations allowed in pretreatment permits, so the idea of
direct discharge from the manufacturing facility to the POTW would
not be allowed and pretreatment would be needed to meet the limits,
adding still additional costs to the wastewater discharge.
In sumary, it is our company policy to maintain and operate
our own wastewater treatment facilities, when the option is
available. Our records indicate that we can do this more
economically and control the costs more effectively. By keeping
different waste streams segregated a better treatment efficiency

T
• - 2 -
can be obtained. This facility was designed under Textile BACT
guidelines and remains capable of meeting and usually exceeding the
discharge limits allowed under Federal Guidelines for the textile
manufacturing industry. The discharge of this wastewater into the
Dan River would have no significant impact on the water quality of
the stream because Dan River has a 7Q10 of 314 cfs and with a
discharge of .5 MGD and low pollutant concentration.
This information should be sufficent to justify the continued
existing treatment alternatives and discharge.

SLUDGE PLAN
NEW STREET WWTP
This facility was designed with a sludge lagoon for temporary
storage of biosolids wasted from the system. The capacity of the
lagoon is 100, 000 gallons. At present it is only at sixty percent
capacity.
The WWTP currently has a low organic loading compared to
design capacity. The system requires a minimal amount of solids
wasting to operate efficiently. At present only several thousand
gallons of dilute concentration are wasted each week to the lagoon.
The water evaporates and leaves a minimal amount of residual
biosolids actually stored in the lagoon. Additional storage
capacity is curently available for continued operation of this
lagoon for many years.

_lam
cc: Permits and Engineering
•
Technical Support Branch
County Health Dept.
Central Files
WSRO
SOC PRIORITY PROJECT: Yes No X
If Yes, SOC No.
To: Permits and Engineering Unit
Water Quality Section
Attention:
Date: September 12, 1996
NPDES STAFF REPORT AND RECOMMENDATION
County Rockingham
Permit No. NC0001643
PART I - GENERAL INFORMATION
1. Facility and Address: Fieldcrest Cannon, Inc.
New Street WWTP
Eden, N.C. 27288
2. Date of Investigation: 960911
3 . Report Prepared by: David Russell, WSRO
4. Persons Contacted and Telephone Number: Shawn Bowers, ORC
(910) 627-3772 Battle Moore, Environmental Engineer (704)
939-2714
5. Directions to Site: From Winston-Salem, travel US 158E, NC
65E, NC 68N, US 220N, NC 135E, NC 770 truck route east, NC
14N. Turn right on Stadium Drive, then right on New Street.
Plant is at end of street.
6. Discharge Points(s) , List for all discharge points:
Latitude: 36° 29' 33" Longitude: 79° 42' 15"
U.S.G.S. Quad No. B20NW U.S.G.S. Quad Name Southeast Eden
7. Site size and expansion area consistent with application?
X Yes No If No, explain:
8. Topography (relationship to flood plain included) : Well
above the flood plain.
9. Location of nearest dwelling: None within 1000' .

10. Receiving stream or affected surface waters: Dan River
a. Classification "C"
b. River Basin and Subbasin No. : 030203
c. Describe receiving stream features and pertinent
downstream uses: Eden Mebane Bridge WWTP, Duke Power
Dan River Steam Station and Miller Brewing discharge
upstream of Fieldcrest. Eden Dry Creek WWTP discharges
downstream of Fieldcrest.
Part II - DESCRIPTION OF DISCHARGE AND TREATMENT WORKS
1. a. Volume of Wastewater to be permitted: 0.50 MGD
(Ultimate Design Capacity)
b. What is the current permitted capacity of the Waste
Water Treatment facility? 0.50 mgd
c. Actual treatment capacity of the current facility
(current design capacity) ? 0,50 mgd
d. Date(s) and construction activities allowed by previous
Authorizations to Construct issued in the previous two
years.
e. Please provide a description of existing or
substantially constructed wastewater treatment
facilities; Influent pumps, screening, aeration basin,
clarifiers, chlorine contact basin, flow measurement,
sludge holding basin.
f. Please provide a description of proposed wastewater
treatment facilities.
g. Possible toxic impacts to surface waters:
h. Pretreatment Program (POTWs only) :
in development approved
should be required not needed
2. Residuals handling and utilization/disposal scheme: WWTP is
very underloaded, wasted sludge is stored in the sludge
holding basin.
a. If residuals are being land applied, please specify DEM
Permit No.
Residuals Contractor
NPDES Permit Staff Report
Version 10/92
Page 2

r•
•
Telephone No.
b. Residuals stabilization: PSRP PFRP
Other
c. Landfill:
d. Other disposal/utilization scheme (Specify) :
3. Treatment plant classification (attach completed rating
sheet) . II
4. SIC Code(s) : 2211
Primary 14 Secondary 02 16 55
Main Treatment Unit Code: 0 5 0 - 4
PART III - OTHER PERTINENT INFORMATION
1. Is this facility being constructed with Construction Grant
Funds or are any public monies involved. (municipals only) ?
2. Special monitoring or limitations (including toxicity)
requests:
3. Important SOC, JOC or Compliance Schedule dates: (Please
indicate)
Date
Submission of Plans and Specifications
Begin Construction
Complete Construction
4. Alternative Analysis Evaluation: Has the facility evaluated
all of the non-discharge options available. Please provide
regional perspective for each option evaluated. Unknown if
other alternatives have been evaluated.
Spray Irrigation:
Connection to Regional Sewer System:
Subsurface:
Other disposal options:
5. Other Special Items:
NPDES Permit Staff Report
Version 10/92
Page 3

r
.
PART IV - EVALUATION AND RECOMMENDATIONS
This 0.5 mgd WWTP treats an average of 0. 157 mgd of
wastewater. Approximately 6, 000 gpd is domestic waste, the
majority of the flow is non-BOD laden cooling water. As a
result, the system is organically underloaded and has produced
limited solids. Limits are consistently met and the plant is
well maintained.
Recommend that the permit be reissued.
S gnature of report preparer
Water Qualit Region Supervisor
fr/(— c
Date
NPDES Permit Staff Report
Version 10/92
Page 4