NC0004243_Draft Permit_20170809

Water Resources
ENVIRONMENTAL QUALITY
ROY COOPER
cvwmor
MICHAEL S_ REGAN
&21v &e?eloy
S. JAY ZIMMERMAN
L maff
August 9, 2017
Mr. John Moss
Facilities Engineering Manager
Coats American
630 American Thread Road
Marion, NC 28752
Subject: Draft NPDES Permit Renewal
Permit NC0004243
Coats American -Sevier Plant
McDowell County
Class 3 Facility
SIC Code 2269
Dear Mr. Moss:
Enclosed with flus letter is a copy of the Draft NPDES permit renewal for your facility. Please
review this draft carefully to ensure thorough understanding of the requirements and conditions it
contains. There are several changes from the existing perms, including the following:
• Receiving stream (North Folk Catawba River) has been reclassified from class C to class
WS -IV on July 1St, 2017. In accordance with 15A NCAC 2B .0200, limitation for total
PAHs (Polycyclic Aromatic Hydrocarbons) was added to the permit as required for WS -
IV waters [See A. (1)].
• Special condition A. (4) was added for total PAHs monitoring requirement. If the first four
samples all showed total PAHs less than detection, at detection level of 0.5 µg/L, the
monitoring for total PAHs can be eliminated. If total PAHs is detected in any of these four
sampling events, quarterly testing is required until expiration of this permit.
• Limitations for total chromium were changed from 1.751bs/day to 1.3 lbs/day for monthly
average, and from 3.5 lbs/day to 1.6 lbs/day for daily maximum based on hexavalent
chromium limits in accordance with 15A NCAC 2B 0200 to assure no water quality
standard is exceeded [See A. (1)].
State of North Carolina I Environmental Quality I Water Resources
1617 Mail Service Center I Raleigh, North Carolina 27699-1617
919 807 6300

Page 12
•
Limitations for total residual chlorine (TRC) were changed from 17 gg/L to 28 gg/L in
accordance with the NC water quality standard for protection of aquatic life and the Waste
Load Allocations [See A. (1)].
• Effluent and upstream hardness quarterly monitoring has been added to the permit as
required by the implementation of the new dissolved metal standards [See A. (1) and A.
(2)]
• histream monitoring at upstream and downstream Limekiln Creek has been added to the
permit due to potential exceedance of surface water standards [See A. (2]
• Effluent data for copper did not demonstrate reasonable potential to exceed applicable
water quality standards/criteria, but the maximum predicted concentration was greater
than 50% of the allowable concentration. Monitoring for total copper was changed to
quarterly in this permit [See A. (1)].
• Monitoring for chlorides has been removed from Effluent Limitations and Monitoring
Requirements [See A. (1)] based on no reasonable potential to exceed water quality
standards.
• Some of the wording has changed in Special Condition A. (3), Chronic Toxicity Permit
Limit, please review each paragraph carefully.
• One effluent data reported for silver was less than detection, at a detection level of less than
5 µg/L. In accordance with 15A NCAC 2B .0500 all test procedures must produce detection
and reporting levels that are below the permit discharge requirements and all data generated
must be reported to the approved detection level or lower reporting level of the procedure.
Currently, DWR's laboratory identifies the Practical Quantitation Limit (PQL) for silver at
< 1 gg/L. The allowable discharge concentration for your facility is 0.41 µg2. Therefore,
future sampling for silver should analyze down to the lower reporting level of the procedure
or PQLs as listed above. No Imuts or additional monitoring requirements for silver were
added to the permit at this time.
• Federal regulations require electronic submittal of all discharge monitoring reports
(DMRs) and program reports. The requirement to continue reporting discharge monitoring
data electronically using the NC DWR's Electronic Discharge Monitoring Report (eDMR)
internet application has been added to your final NPDES permit. [See Special Condition
A. (5)]
• Regulatory citations have been added to the permit.
Concurrent with this notification the Division is publishing a notice in a newspaper having
circulation in the general McDowell County area, soliciting public comments on this draft
permit. Please provide any written comments you may have to the following: NCDEQ/DWR,
NPDES Permitting Branch, 1617 Mail Service Center, Raleigh, NC 27699-1617 no later than 30
days after receipt of this draft permit.

Page 13
Following the 30 -day public comment period, the Division will review all pertinent comments
and take appropriate action prior to issuing a final permit. If you have questions concerning this
draft permit, please call me at [phone] or by email at [e-mail].
Sincerely,
Bing Bai, Engineer
NPDES Complex Permitting Unit
Hardcopy: NPDES Files
Ecopy: US EPA Region 4
DWR/Aquathc Toxicology Branch/Susan Meadows
DWR/Asheville Regional Office/Water Quality
DWR/Asheville Regional Office/PWS
DWR/Operator Certification Program/Maureen Kinney

Permit NC0004243
STATE OF NORTH CAROLINA
DEPARTMENT OF ENVIRONMENTAL QUALITY
DIVISION OF WATER RESOURCES
PERMIT
TO DISCHARGE WASTEWATER UNDER THE
NATIONAL POLLUTANT DISCHARGE ELIMINATION SYSTEM
In compliance with the provisions of North Carolina General Statute 143-215.1, other lawful standards and
regulations promulgated and adopted by the North Carolina Environmental Management Commission, and the
Federal Water Pollution Control Act, as amended,
Coats American, Inc.
is hereby authorized to discharge wastewater from a facility located at the
Sevier Finishing Plant
630 American Thread Road
Marion, North Carolina
McDowell County
to receiving waters designated as North Fork Catawba River in the Catawba River Basin in accordance with
effluent limitations, monitoring requirements, and other conditions set forth in Parts I, H, III and IV hereof.
This permit shall become effective September xx, 2017
This permit and authorization to discharge shall expire at midnight on December 31, 2021.
Signed this day September xx, 2017
Draft
S Jay Zimmerman, P G , Director
Division of Water Resources
By Authority of the Environmental Management Commission

Pernnt NC0004243
SUPPLEMENT TO PERMIT COVER SHEET
All previous NPDES Permits issued to this facility, whether for operation or discharge are hereby revoked, and as
of this issuance, any previously issued permit -:)eanng this number is no longer effective Therefore, the exclusive
authority to operate and discharge from this facility arises under the permit conditions, requirements, terms, and
provisions included herein.
Coats American, Inc. is hereby authorized to:
1. Continue to operate an existing 2.0 MGD wastewater treatment facility consisting of the following
components.
• an influent equalization basin
• an aeration basin
• two clarifiers with return sludge pumps
• polishing pond (not in use)
• chlorination tank and dechlorination
• final aeration pond
• flow meter
The facility is located at the Sevier Finishing Plant on 630 American Thread Road in Manon, McDowell
County.
2. Discharge from said treatment works via Outfall 001, at the location specified on the attached map into the
North Fork Catawba River currently classified as WS -IV waters in subbasin 03-08-30 [HUC: 03050101]
of the Catawba River Basin.
Page 2 of 9

Perriut NC0004243
Part I
A. (1) EFFLUENT LIMITATIONS AND MONITORING REQUIREMENTS
[ 15A NCAC 0213.0400 et seq., 15A NCAC 0213.0500 et seq.]
During the period beginning on the effective date of the pertmt and lasting until expiration, the Permittee is
authorized to discharge treated wastewater from Outfall 001. Such discharges shall be limited and monitored'
by the Permittee as specified below.
Effluent Characteristics
Parameter Code
Discharge Limitations
Monitoring Requirements
Monthly
Average
Daily
Maximum
Measurement
Frequency
Sample
Type
Sample Location
Flow 50050
2 0 MGD
Continuous
Recording
Influent or Effluent
BOD, 5 -day, 20 °C QD310
94 3 lbs/day
188 5 lbs/day
3/Week
Composite
Effluent
COD 00340
1172 3 lbs/day
2344 5 lbs/day
3/Week
Composite
Effluent
Total Suspended Solids QD530
241 1 lbs/day
482 2 lbs/day
3/Week
Composite
Effluent
Sulfide 00745
3 4 lbs/day
'6.8 lbs/day
Weekly
Grab
Effluent
Total Chromium 01034
13 lbs/day
16 lbs/day
Weekly
Composite
Effluent
Phenols 32730
17 lbs/day
3 4 lbs/day
Weekly
Grab
Effluent
Fecal Coliform
31616
(geometric mean)
'
200/100m1
400/100m1
Weekly
Grab
Effluent
Temperature (°C) 00010
Daily
Grab
Effluent
pH 00400
Between 6 0 and 9 0 s u
3/Week
Grab
Effluent
Total Residual Chlorine 2 0060
28 µg/L
2/Week
Grab
Effluent
NH3-N C0610
Weekly
Composite
Effluent
Total Copper 01042
Quarterly
Composite
Effluent
Total Nitrogen
(NO2+NO3+TKN) 3 C0600
Monthly
Composite
Effluent
Total(Polycyclic
Aromatictic Hydrocarbons) 4 51614
Hydrocarbons)
0 019 µg/L
0 019 µg/L
Quarterly
Composite
Effluent
Total Phosphorus C0665
Monthly
Composite
Effluent
Chronic Toxicity 5 TGP3B
Quarterly
Composite
Effluent
Hardness- Total as [CaCO3 00900
or (Ca + Mg)] (mg/L)
Quarterly
Composite
Effluent
Footnotes
1 The permittee shall subnut discharge monitoring reports electronically using the NC DWR's eDMR application
system [see A (5)]
2 Total residual chlorine shall be monitored only if chlorine is used for disinfection The Division shall consider all
effluent TRC values reported below 50 µg/L to be in compliance with the permit However, the pernuttee shall
continue to record and subrmt all values reported by a North Carolina certified laboratory
3 TN = TKN + NO3-N + NO2-N where TN is Total Nitrogen, TKN is Total Kjeldahl Nitrogen, and NO3-N + NO2-N
are Nitrate and Nitrite Nitrogen, respectively
4 The Division shall consider all effluent Total PA -Hs values reported less than the detection level of 0 5 µg/L to be in
compliance with the permit See Special Condition A (4) for total PAHs monitoring requirement
5 Chronic Toxicity (Ceriodaphnia) linut at 15% with testing in February, May, August, and November [see A (3)]
There shall be no discharge of floating solids or visible foam in other than trace amounts.
Page 3 of 9

Peurur NCO004243
A. (2) INSTREAM MONITORING REQUIREMENTS
[15A NGAG 02B„0500 et seq,]
Parameters
Measurement Frequency
Sample Type
Sample
Location'
Dissolved Oxygen (i -ng/(,)
pH
TRC (pg/Q
Total Hardness as [,GaCO,, or
Quarterly
Grab
U1, Dl
(Ca- Mg)j (mg/L)
Total Copper (µ,g/f-)
Total PAHS (Vg/L,)`'
Total Hardness as [CaCO; or
Quarterly
Grab
U?,
(Ca + Mg)] (mgfL)
Votes
L See map below for sampling locations,
Ul, Limekiln Greek -Lip itreain of Coats American Facility, Lat-35°4718 5” N, Long', 82'0 V56" W
D1_ himekiln Creek downstream of Coats American Facility, Lat-35047'35" N, Long 82°01'08"W
U2: North Fork Catawba River upstream of Outfall 001, Lat 35°4737 2" N, Long- 82°01'09" W
2 See Special Condition Aa (4) for total PAHs Monitoring requirement,
Page 4 of 9

Permit NC0004243
A. (3) CHRONIC TOXICITY PERMIT LIMIT (QUARTERLY)
[15A NCAC 02B.0200]
The effluent discharge shall at no time exhibit observable inhibition of reproduction or significant mortality to
Ceriodaphnia dubia at an effluent concentration of 15%.
The permit holder shall perform at a minimum, quarterly monitoring using test procedures outlined in the "North
Carolina Ceriodaphnia Chronic Effluent Bioassay Procedure," Revised December 2010, or subsequent versions or
"North Carolina Phase II Chronic Whole Effluent Toxicity Test Procedure" (Revised- December 2010) or
subsequent versions. The tests will be performed during the months of February, May, August, and November.
These months signify the first month of each three-month toxicity testing quarter assigned to the facility Effluent
sampling for this testing must be obtained during representative effluent' discharge and shall be performed at the
NPDES permitted final effluent discharge below all treatment processes.
If the test procedure performed as the first test of any single quarter results in a failure or ChV below the
permit limit, then multiple -concentration testing shall be performed at a minimum, in each of the two
following months as described in "North Carolina Phase II Chronic Whole Effluent Toxicity Test
Procedure" (Revised -December 2010) or subsequent versions.
All toxicity testing results required as part of tlus permit condition will be entered on the Effluent Discharge
Monitoring Form (MR -1) for the months in. which tests were performed, using the parameter code TGP3B for the
pass/fail results and THP313 for the Chronic Value. Additionally, DWR Form AT -3 (original) is to be sent to the
following address:
Attention: North Carolina Division of Water Resources
Water Sciences Section/Aquatic Toxicology Branch
1621 Mail Service Center
Raleigh, NC 276994621
Completed Aquatic Toxicity Test Forms shall be filed with the Water Sciences Section no later than 30 days after
the end of the reporting period for which the report is made.
Test data shall be complete, accurate, include all supporting chemical/physical measurements and all
concentration/response data, and be certified by laboratory supervisor and ORC or approved designate signature.
Total residual chlorine of the effluent toxicity sample must be measured and reported if chlorine is employed for
disinfection of the waste stream
Should there be no discharge of flow from the facility during a month in which toxicity monitoring is required, the
permittee will complete the information located at the top of the aquatic toxicity (AT) test form indicating the
facility name, permit number, pipe number, county, and the month/year of the report with the notation of "No
Flow" in the comment area of the form The report shall be submitted to the Water Sciences Section at the address
cited above.
Should the permittee fail to monitor during a month in which toxicity monitoring is required, monitoring will be
required during the following month. Assessment of toxicity compliance is based on the toxicity testing quarter,
which is the three month time interval that begins on the first day of the month in which toxicity testing is required
by tlus permit and continues until the final day of the third month.
Should any test data from this monitoring requirement or tests performed by the North Carolina Division of Water
Resources indicate potential impacts to the receiving stream, this permit may be re -opened and modified to include
alternate monitoring requirements or limits.
NOTE- Failure to achieve test conditions as specified in the cited document, such as minimum control organism
survival, minimum control organism reproduction, and appropriate environmental controls, shall constitute an
Page 5 of 9

Pernnt NC0004243
invalid test and will require immediate follow-up testing to be completed no later than the last day of the month
following the month of the initial monitoring.
A. (4) TOTAL PAHS (POLYCYCLIC AROMATIC HYDROCARBONS) MONITORING
[ 15A NCAC 02B.02001
The Permittee shall apply quarterly monitoring for total PAHs for both effluent and instream sampling, including
parameters listed below:
1 -Methylnaphthalene
2 -Methylnaphthalene
Benzo(a)anthracene
Benzo(a)pyrene
Benzo(b)fluoranthene
Benzo(g,h,i)perylene
Benzo(k)fluoranthene
Chrysene
Dibenzo(a,h)anthracene
Fluoranthene
Indeno(1,2,3-cd)pyrene
Naphthalene
Phenanthrene
Pyrene
For all 12 sampling events in the first year (4 effluent samples and 8 instream samples), if the total concentrations
of above parameters are all less than detection, at the detection level of 0.5 gg/L as reported in 2016 Coats North
America Site Assessment Report, the Permittee can discontinue monitoring for total PAHs. If any listed parameter
is detected, the Permittee shall keep quarterly monitoring for both effluent and instream samples until the
expiration of this permit.
A. (5) ELECTRONIC REPORTING OF MONITORING REPORTS
[G.S. 143-215.1(b)]
Federal regulations require electronic submittal of all discharge monitoring reports (DMRs) and program reports.
The final NPDES Electronic Reporting Rule was adopted and became effective on December 21, 2015.
NOTE: This special condition supplements or supersedes the following sections within Part II of this permit
(Standard Conditions for NPDES Permits):
• Section B. (11.)
• Section D. (2.)
• Section D. (6.)
• Section E. (5.)
Signatory Requirements
Reporting
Records Retention
Monitoring Reports
1. Reporting Requirements [Supersedes Section D. (2.) and Section E. (5.) (a)1
The permittee shall report discharge monitoring data electronically using the NC DWR's Electronic Discharge
Monitoring Report (eDMR) internet application.
Monitoring results obtained during the previous month(s) shall be summarized for each month and submitted
electronically using eDMR. The eDMR system allows permitted facilities to enter monitoring data and submit
DMRs electronically using the internet. Until such time that the state's eDMR application is compliant with
EPA's Cross -Media Electronic Reporting Regulation (CROMERR), permittees will be required to submit all
discharge monitoring data to the state electronically using eDMR and will be required to complete the eDMR
submission by printing, signing, and submitting one signed original and a copy of the computer printed eDMR
to the following address:
NC DEQ / Division of Water Resources / Water Quality Permitting Section
ATTENTION: Central Files
1617 Mail Service Center
Raleigh, North Carolina 27699-1617
Page 6 of 9

Permit NC0004243
If a permittee is unable to use the eDMR system due to a demonstrated hardship or due to the facility being
physically located in an area where less than 10 percent of the households have broadband access, then a
temporary waiver from the NPDES electronic reporting requirements may be granted and discharge monitoring
data may be submitted on paper DMR forms (MR 1, 1. 1, 2, 3) or alternative forms approved by the Director.
Duplicate signed copies shall be submitted to the mailing address above. See "How to Request a Waiver from
Electronic Reporting" section below.
Regardless of the submission method, the first DMR is due on the last day of the month following the issuance
of the permit or in the case of a new facility, on the last day of the month following the commencement of
discharge.
Starting on December 21, 2020, the permittee must electronically report the following compliance monitoring
data and reports, when applicable:
Sewer Overflow/Bypass Event Reports;
Pretreatment Program Annual Reports; and
Clean Water Act (CWA) Section 316(b) Annual Reports
The permittee may seek an electronic reporting waiver from the Division (see "How to Request a Waiver from
Electronic Reporting" section below).
2. Electronic Submissions
In accordance with 40 CFR 122.41(1)(9), the permittee must identify the initial recipient at the time of each
electronic submission. The permittee should use the EPA's website resources to identify the initial recipient
for the electronic submission.
Initial recipient of electronic NPDES information from NPDES-regulated facilities means the entity (EPA or
the state authorized by EPA to implement the NPDES program) that is the designated entity for receiving
electronic NPDES data [see 40 CFR 127 2(b)].
EPA plans to establish a website that will also link to the appropriate electronic reporting tool for each type of
electronic submission and for each state Instructions on how to access and use the appropriate electronic
reporting tool will be available as well. Information on EPA's NPDES Electronic Reporting Rule is found at:
https://www federalre ister.gov/documents/2015/10/22/2015-24954/national-t)ollutant-discharge-elimmation-
system-npdes-electronic-reporting rule.
Electronic submissions must start by the dates listed in the "Reporting Requirements" section above.
3. How to Request a Waiver from Electronic Reporting
The permittee may seek a temporary electronic reporting waiver from the Division To obtain an electronic
reporting waiver, a permittee must first submit an electronic reporting waiver request to the Division.
Requests for temporary electronic reporting waivers must be submitted in writing to the Division for written
approval at least sixty (60) days prior to the date the facility would be required under this permit to begin
submitting monitoring data and reports. The duration of a temporary waiver shall not exceed 5 years and shall
thereupon expire. At such time, monitoring data and reports shall be submitted electronically to the Division
unless the permittee re -applies for and is granted a new temporary electronic reporting waiver by the Division.
Approved electronic reporting waivers are not transferrable. Only permittees with an approved reporting
waiver request may submit monitoring data and reports on paper to the Division for the period that the
approved reporting waiver request is effective.
Page 7 of 9

Permit NC0004243
Information on eDMR and the application for a temporary electronic reporting waiver are found on the
following web page:
http://deq.nc Qov/about/divisions/water-resources/edmr
4. Signatory Requirements [Supplements Section B. (11.) (b) and Supersedes Section B. (11.) (d)l
All eDMRs submitted to the permit issuing authority shall be signed by a person described in Part II, Section
B. (I 1.)(a) or by a duly authorized representative of that person as described in Part H, Section B. (11.)(b). A
person, and not a position, must be delega.ed signatory authority for eDMR reporting purposes.
For eDMR submissions, the person signing and submitting the DMR must obtain an eDMR user account and
login credentials to access the eDMR system. For more information on North Carolina's eDMR system,
registering for eDMR and obtaining an eDMR user account, please visit the following web page:
http //deq nc.gov/about/divisions/water-resources/edmr
Certification. Any person submitting an Electronic DMR using the state's eDMR system shall make the
following certification [40 CFR 122.221. NO OTHER STATEMENTS OF CERTIFICATION WILL BE
ACCEPTED -
7 cert, under penalty of law, that this document and all attachments were prepared under my direction or
supervision in accordance with a system designed to assure that qualified personnel properly gather and
evaluate the information submitted. Based on my inquiry of the person or persons who manage the system, or
those persons directly responsible for gathering the information, the information submitted is, to the best of my
knowledge and belief, true, accurate, and complete. I am aware that there are significant penalties for
submitting false information, including the possibility offines and imprisonment for knowing violations. "
5. Records Retention [Supplements Section D. (6.)]
The permittee shall retain records of all Discharge Monitoring Reports, including eDMR submissions. These
records or copies shall be maintained for a period of at least 3 years from the date of the report This period
may be extended by request of the Director at any time [40 CFR 122.41].
Page 8 of 9

Permit NC0004243
Coats American, Inc. - NC0004243
USGS Quad Name: Little Switzerland Lat.: 35°47'35"
Receiving Stream: N. Fork Catawba River Long.: 82101'09"
Stream Class: WS -IV
Subbasin: Catawba- 03-08-30
Facility
Location
)rt1t Not to SCALE