NC0002305_Draft Permit_20171018

Water Resources
ENVIRONMENTAL QUALITY
October 18, 2017
Mr. Norman Johnson, Environmental Manager
Lear Corporation
1754 NC Hwy 903
Kenansville, North Carolina 28349
Dear Mr. Johnson:
ROY COOPER
Governor
MICHAEL S REGAN
Secretat7,
S JAY ZIMMERMAN
Directoi
Subject: Draft NPDES Permit Renewal
Permit NC0002305
Lear Corporation WWTP
Duplin County
Class III Facility
SIC 2258 & 2262
Enclosed with this 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 permit, including the following:
• Removed Total Copper and Total Zinc monitoring. Reasonable potential analysis indicated the
predicted concentration was less than 50% of the allowable WQBEL (see A (1.)).
• Removed MBAS monitoring, no longer a pollutant of interest (see A (1.)).
• Increased the monitoring frequency of Total Cyanide to weekly and corrected the WQBEL.
Monthly data indicated isolated samples would have exceeded the corrected WQBEL (see A
(1 •))-
• Calculated and decreased TBEL (mass based limits) for BOD, COD, TSS, Sulfide, Total Phenols,
and Total Chromium based on last 3 years production and on 40 CFR 410 Subpart E Knit Fabric
Finishing applicable BAT/BPT factors.
• Added conditional Chromium VI concentration monitoring. No Chromium VI data available but
if Total Chromium concentration exceeds 41.8 gg/L then will need Chromium VI concentration
data to conduct an evaluation at next permit renewal (see A (1.)).
• The NC 2007-2014 Water Quality Standard (WQS) Triennial Review was approved by the NC
Environmental Management Commission (EMC) on November 13, 2014. The US EPA
subsequently approved the WQS revisions on April 6, 2016 with some exceptions. The NC
Division of Water Resources NPDES Permitting Unit is required to implement the new dissolved
metal standards in all permits public noticed after April 6, 2016.
State of North Carolina I Environmental Quality I Water Resources
512 N Salisbury Street 1 1612 Mail Service Center I Raleigh, North Carolina 27699-1612
919 807 6464

Page 12
The new standards for most metals include acute standards. Further, the freshwater standards for
several metals are expressed as the dissolved form of the metals and seven metals (cadmium,
chromium III, copper, lead, nickel, silver, zinc) have hardness -dependent equations. As a result,
the NPDES Permitting Unit may request as part of the next permit renewal site-specific effluent
hardness data and instream hardness data, upstream of the discharge, for this facility in order to
calculate metal permit limitations. Effective with this permit renewal, no hardness dependent
metals are being monitored in this permit.
• 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. The requirement to begin reporting discharge monitoring data
electronically using the NC DWR's Electronic Discharge Monitoring Report (eDMR) internet
application has been added to this permit [See Special Condition A (3)]
For information on eDMR, registering for eDMR and obtaining an eDMR user account, please
visit the following web page: http://deq.ne.gov/about/divisions/water-resources/ed=.
For more information on EPA's final NPDES Electronic Reporting Rule, please visit the
following web site: https://www.federalregister.gov/documents/2015/10/22/2015-24954/national-
pollutant-discharge-elumnation-system-npdes-electronic-reporting-rule
The NPDES Standard Conditions (Part IL III, and IV) are not included with this draft. They can be found
at the following link if you would like to review them in conjunction with this draft permit.
http //ncdenr s3.amazonaws.com/s3fs-
public/Water%200uality/Surface%20Water%20Protection/NPDES/MISC/NPDES%20 Standard%20Con
dations-Boilerplate-DWR-SWP-NPDES-20150410 pdf
Concurrent with this notification the Division is publishing a notice in a newspaper having
circulation in the general Template 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.
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,
Ron Berry, Engineer
NPDES Complex Permitting Unit
Hardcopy: NPDES Files
Ecopy: US EPA Region 4
DWR/Aquatic Toxicology Branch/Susan Meadows
DWR/Wilmington Regional Office / Water Quality
DWR/Operator Certification Unit/Maureen Kmney

Permit NC0002305
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 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,
Lear Corporation (formerly Guilford Mills, Inc.)
is hereby authorized to discharge wastewater from outfall located at the
Lear Corporation Wastewater Treatment Plant
1754 NC Highway 903 Kenansville
Duplin County
to receiving waters designated as the Northeast Cape Fear River within the Cape Fear River
Basin in accordance with effluent limitations, monitoring requirements, and other conditions
set forth in Parts I, II, III, and IV hereof.
This permit shall become TBD.
This permit and authorization to discharge shall expire at midnight on December 31, 2022.
Signed this day . ... .. TBD.
S. Jay Zimmerman, P.G., Director
Division of Water Resources
By Authority of the Environmental Management Commission
Page 1 of 9

Permit NC0002305
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 bearing this number is
no longer effective. Therefore, the exclusive authority to operate and discharge from this
facility arises under the permit conditions, requirements, terms, and provisions described
herein.
Lear Corporation
is hereby authorized to:
1. Continue discharging 1.5 MGD of treated industrial wastewater from the existing
wastewater treatment facility that includes the following components:
o Mechanical bar screen
o Influent meter with Parshall flume and continuous recording
o One (1) 2,000,000 gallon influent equalization basin with three (3) floating
aerators and transfer pumps
o One (1) 2,000,000 gallon aeration basin with eight (8) floating aerators
o Splitter box
o Chemical coagulant and polymer flocculant addition systems
o Two (2) 55 ft diameter secondary clarifiers with RAS and WAS transfer pumps
o Alum/caustic dispensing system
o Flash tank
o One (1) 60 ft diameter tertiary clarifier with RAS/WAS transfer pumps
o Effluent pump station
o Chlorination with contact tank
o De -chlorination addition
o Effluent flow meter with continuous recording
o Effluent composite sampler
o Sludge thickener tank
o One (1) 1,000,000 gallon sludge digester with floating aerator and transfer pump
o One (1) 500,000 gallon sludge storage tank with floating aerator
o One (1) 50,000 gallon filtrate tank with transfer pump
o Sludge drum thickener
o Twelve (12) sand sludge -drying beds with liquid recovery pumps
This facility is located at the Lear Corporation Wastewater Treatment Plant, 1754 NC
Highway 903, Kenansville in Duplin County.
2. To discharge from said treatment facility through Outfall 001 at a specified location (see
attached map) into the Northeast Cape Fear River, a waterbody classified as C -Swamp waters
within the Cape Fear River Basin.
Page 2 of 9

Permit NC0002305
Part I
A (l.) EFFLUENT LIMITATIONS AND MONITORING REQUIREMENTS
[15A NCAC 02B .0400 et seq., 02B .0500 et seq.]
During the period beginning on the effective date of the permit and lasting until expiration,
the Permittee is authorized to discharge from Outfall 001. Such discharges shall be limited
and monitored 1 by the Permittee as specified below:
Page 3 of 9
LIMITS
MONITORING REQUIREMENTS
EFFLUENT
Measurement
Sample
Sample
CHARACTERISTICS
Monthly Average
Daily Maximum
Frequency
Type
Location 2
Flow
1.5 MGD
Continuous
Recording
Influent or
Parameter Code 50050
. /
Effluent
BOD, day,
129.4 pounds/day
258.9 pounds/day
3/Week
Composite
Effluent
Parameter Codee QD310
COD
2,071.0 pounds/day
4,142.Opounds/day
3/Week
Composite
Effluent
Parameter Code 00340
Total Suspended Solids
564.3 pounds/day
1,128.7 pounds/day
3/Week
Composite
Effluent
Parameter Code QD530
pH
Not less than 6.0 S.U. nor greater than
3/Week
Grab
Effluent
Parameter Code 00400
9.0 S.U.
Total Residual Chlorine 3
28 µg/L
3/Week
Grab
Effluent
Parameter Code 50060
Dissolved Oxygen
Not less than 6.0 mg/L, daily average
3/Week
Grab
Effluent
Parameter Code 00300
Dissolved Oxygen, mg/L
3/Week
Grab
U, D
(June 1 — September 30)
Dissolved Oxygen, mg/L
Weekly
Grab
U, D
(October 1 — May 31)
Temperature,"C
3/Week
Grab
Effluent
Parameter Code 00010
Temperature, °C
3/Week
Grab
U, D
(June 1 — September 30)
Temperature, °C
Weekly
Grab
U, D
(October 1 — May 31)
Conductivity, µmhos/cm
3/Week
Grab
Effluent
Parameter Code 00094
Conductivity, µmhos/cm
3/Week
Grab
U, D
(June 1 — September 30)
Conductivity, µmhos/cm
Weekly
Grab
U, D
(October 1 — May 31)
Fecal Coliform
(geometric mean)
200 / 100 ml
400 / 100 ml
Weekly
Grab
Effluent
Parameter Code 31616
Sulfide
5.2 pounds/day
10.4 pounds/day
Weekly
Grab
Effluent
Parameter Code 00745
Page 3 of 9

Permit NC0002305
(Continued A. (1) EFFLUENT LIMITATIONS AND MONITORING REQUIREMENTS)
EFFLUENT
LIMITS
MONITORING REQUIREMENTS
Monthly Average
Daily Maximum
Measurement
Frequency
Sample
Type
Sample 2
Location
CHARACTERISTICS
Total Phenols
2.6 pounds/day
5.2 pounds/day
Weekly
Grab
Effluent
Parameter Code 32730
Total Chromium 4
2.6 pounds/day
5.2 pounds/day
Weekly
Composite
Effluent
Parameter Code 01034
Chromium VI 4
Weekly
Composite
Effluent
Parameter Code 82399
Total Cyanide, gg/L
19 gg/L
73 gg/L'
Weekly
Composite
Effluent
Parameter Code 00720
Oil and Grease
30.0 mg/L
45.0 mg/L
2/Month
Grab
Effluent
Parameter Code 00556
Total Nitrogen (TN), mg/L
TN = TKN + (NO2-N+NO3-N)
Monitor &.Report
Monthly
Composite
Effluent
Parameter Code C0600
`
Total Phosphorus,
Monitor & Report
Monthly
Composite
Effluent
Parameter Code C066565
Chronic Toxicity 5
Parameter Code TGP3B
Quarterly
Composite
Effluent
Footnotes:
1. The Permittee shall submit Discharge Monitoring Reports electronically using
NCDWR's eDMR application_ system. See Special Condition A (3.).
2. U = Upstream in Goshen Swamp at Highway 11 Bridge. D = Downstream in NE
Cape Fear River at Sarecta Bridge.
3. The Division shall consider all effluent Total Residual Chlorine values reported
below 50 µg/l, to be in compliance with the permit. However, the Permittee shall
continue to record and submit all values reported by a North Carolina certified
laboratory (including field certified), even if these values fall below 50 gg/L.
4. Measurement for Chromium VI is waived until a Total Chromium concentration
measurement is > 41.8 gg/L. Once a single Total Chromium concentration
measurements is > 41.8 µg/L then weekly measurements of Chromium VI shall
commence immediately and continue in conjunction with Total Chromium
measurements.
5. Chronic Toxicity, Ceriodapknia dubia, 7 day, P/F at 27%; during January, April,
July, and October. See Special Condition A (2.).
THERE SHALL BE NO DISCHARGE OF FLOATING SOLIDS OR VISIBLE FOAM IN
OTHER THAN TRACE AMOUNTS.
Page 4of9

Permit NC0002305
A (2.) CHRONIC TOXICITY PERMIT LIMIT (Quarterly)
[I 5A NCAC 02B .0200 et seq.]
The effluent discharge shall at no time exhibit observable inhibition of reproduction or
significant mortality to Ceriodaphnia dubia at an effluent concentration of 27%.
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 January, April, July and October 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 this permit condition will be entered on the
Effluent Discharge Monitoring Form (MR -1) for the months in which tests were performed,
using the parameter code TGP313 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 27699-1621
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.
Page 5 of 9

Permit NC0002305
(Continued A (2.) CHRONIC TOXICITY PERMIT LIMIT)
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 this 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 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 (3.) 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.) Signatory Requirements
• Section D. (2.)
• Section D. (6.)
• Section E. (5.)
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
Page 6 of 9

Permit NC0002305
(Continued A (3.) ELECTRONIC REPORTING OF MONITORING REPORTS)
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
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:
Page 7 of 9

Permit NC0002305
(Continued A (3.) ELECTRONIC REPORTING OF MONITORING REPORTS)
https://www.federalre ig ster.govldocamentsl2015/10/22/2015-24954/national-pollutant-
discharge-elimination-system-npdes-electronic-reportin -rule
Electronic submissions must start by the dates listed in the "Reporting Requirements"
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 Div_sion. 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.
Information on eDMR and the application for a temporary electronic reporting waiver are
found on the following web page:
http://deq.nc. gov/about/divisions/�.vater-resources/edmr
4. Sisnatory Requirements [Supplements Section B. (11.) (b) and Supersedes
Section B. (11.) (d)1
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 II, Section B. (11.)(b). A person, and not a position, must be
delegated 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:
htip://deq.nc.gov/about/divisions/water-resources/edmr
Page 8 of 9

Permit NC0002305
(Continued A (3.) ELECTRONIC REPORTING OF MONITORING REPORTS)
Certification. Any person submitting an electronic DMR using the state's eDMR system
shall make the following certification [40 CFR 122.22]. NO OTHER STATEMENTS
OF CERTIFICATION WILL BE ACCEPTED:
"I certify, 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 of fines 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 9of9

•
NC HWY 11/903
4 Ru Millers
Bridge I _
Nor 2
-
-
Outfall 001
Lear Corporation Upstream
•s
a
r
Downstream -
i
1:80,000
SCALE: 1:24 000
USGS Quad: G27 SE Albertson, NC
Outfall Facility
Latitude: 350 l' 0.4" N 350 1'38" N
Longitude: 77° 50'46.6" W 770 51'38" W r.._. .
Facility L
P'
Stream Class: C, Sw ocation
North
Subbasin: 03-06-22 HUC: 03030007 Lear Corporation NC0002305
Receiving Stream: NE Cape Fear River Duplin County

s