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Home My WebLink AboutNC0023876_Modified Industrial User_20180403 _ 'g cyc,TONrr0� A0. C' City ofBurCin ton c 48 14,1x9'' Robert C. Patterson,Jr., T.E. Water Resources Director April 3, 2018 RECEIVED/DENR/DWR Ms. Vivien Zhong Division of Water Resources APR 9 2018 Department of Environmental Quality Water ResourCes 1617 Mail Service Center i'errnitting section Raleigh,N.C. 27699-1617 Subject: Modified Industrial User Permit#0057 Dear Ms. Zhong, Please find enclosed a copy of the modified permit pages for Lemco Hosiery Mills, Inc., which include the Cover, History, Limits, and Synopsis. This permit was modified increasing the copper permit limit to 1.50 lbs/day from 0.10 lbs/day. With these modified permit pages,please find an updated allocation table, a copy of the letter asking for an increase in the permit copper limit, and a transmittal letter to Lemco. If you have any questions please feel free to call me at 336-222-5133 Sincerely, RLA, c Pec14 Robert C. Patterson, Jr., P.E. Water Resources Director City of Burlington Connecting the Triad and the Triangle 1302 Belmont Street PO Box 1358—Burlington,NC 27216 336-222-5133—Fax 336-570-6175—www BurlingtonNC gov , (GTONN0F, �...4 i City ofBurlington Iry ,�.lad B i4,1,c,„ Robert C. Patterson,Jr., P.E. Water Resources Director March 23, 2018 Mr. Roger Page1. 6C '/VED/D Lemco Hosiery Mills, Inc. EENR/ ®WR 766 Koury Drive APR o 2018 P.O. Box 2098 _Water des Burlington,N.C. 27215 Perrnitti �e rce tion Subject: Industrial User Permit#0057 Permit Modification Dear Mr. Page, The City of Burlington modified your permit in regards to the copper limit. Effective March 26, 2018, the permit limit for copper will increase from 0.10 lbs/day to 1.50 lbs/day. Please replace this Cover page, Modification page, Permit Limits page, and Synopsis page in your Industrial User Permit with the one you currently have that reflects this change. If you have any questions,please feel free to call me or Kristy King at(336) 222-5133. Sincerely, !?ate. CiP ) tt Robert C. Patterson, Jr., P.E. Water Resources Director City of Burlington Connecting the Triad and the Triangle 1302 Belmont Street—PO Box 1358—Burlington,NC 27216 336-222-5133—Fax 336-570-6175—www BurlingtonNC gov r ' City of Burlington Control Authority and/or Municipality PERMIT Industrial User Pretreatment Permit(IUP) To Discharge Wastewater Under the Industrial Pretreatment Program 0057 N/A IUP Number 40 CFR Category/if Applicable) In compliance with the provisions of North Carolina General Statute 143-215.1, any applicable federal categorical pretreatment regulations, all other lawful standards and regulations promulgated and adopted by the North Carolina Environmental Management Commission, and the Control Authority and/or Municipality Sewer Use Ordinance. The following Industry, hereafter referred to by name or as the permittee: Industry name,permittee Lemco Mills Facility Located at Street Address 766 Koury Drive City Burlington State,Zip North Carolina 27215 is hereby authorized to discharge wastewater from the facility located at the above listed address into the sanitary sewer collection system and the wastewater treatment facility of the Control Authority and/or Municipality listed below: IUP Control Authority and/or Municipality WWTP name South Burlington Wastewater Treatment Plant NPDES Number NC0023876 W WTP Address Boy Wood Road City,State,Zip Burlington,North Carolina 27215 in accordance with effluent limitations, monitoring requirements, and all other conditions set forth in Parts I, II, and III of this Industrial User Pretreatment Permit(IUP). Effective date, this permit and the authorization to discharge shall become effective at midnight on this date March 26, 2018 Expiration date,this permit and the authorization to discharge shall expire at midnight on this date December 31, 2021 Rtio,f C- o3/7-31z616 Water Resources Director Water Resources Director/Date Title Industrial User Pretreatment Permit (IUP) PART I Specific Conditions Continued: IUP History IUP, PART I, OUTLINE: A.) IUP Basic Information B.) IUP Modification History C.) Authorization Statement D.) Description of Discharges E.) Schematic and Monitoring Locations F.) Effluent Limits &Monitoring Requirements G.) Definitions and Limit Page(s)notes A. IUP Basic Information: Receiving Control Authority&WWTP name POTW NPDES# South Burlington Wastewater Treatment Plant NC0023876 IUP Name IUP Number Lemco Mills 0057 IUP Effective date Pipe Numbers,list all regulated pipes March 26, 2018 01 IUP Expiration date IUP 40 CFR#(if applicable),or N/A December 31, 2021 N/A B. IUP History. Effective New/Renewal or Description of changes over previous IUP. Date Modification 1/1/1997 Renewal New Permit issued,former permit expired December 31, 1996. 9/30/1997 Modification Ph limit changed to 5 to 10 units. 1/1/2002 Renewal New Permit issued,former permit expired December 31, 2001 and Industry will sample semi-annually and POTW will sample semi- annually. Temperature Limit increased to 50 degree Celsius from 40 degree Celsius. 2/01/2002 Modification Abbreviated Bioassay for toxicity monitoring no longer a permit requirement. 11/01/2002 Modification Ph limit changed to 5 to 11 units.. 2 Industrial User Pretreatment Permit (IUP) PART I Specific Conditions Continued: IUP History 7/01/2003 Modification Monitoring for Aqueous CTAS and Surfactants as MBAS no longer a permit requirement. 1/1/2007 Renewal New Permit issued, former permit expired December 31, 2006. 1/01/2012 Renewal New Industrial User Permit issued, former permit expired December 31, 2011. 1/1/2017 Renewal/ New Industrial User Permit issued, former Modification permit expired December 31, 2016. Quarterly sampling schedule will change to POTW sampling 1st and 3rd quarters of the calendar year, and industry will sample 2nd and 4th quarters of the calendar year. 3/26/2018 Modification Copper limit increased from 0.1 lbs./day to 1.5 lbs./day. 3 Receiving POTW name=> South Burlington WWTP IU name=> Lemco Mills IUP, Part 1 Section F: Receiving POTW NPDES#_> NC0023876 IUP#_> 0057 Effluent Limits and Monitoring Requirements Effective date for these Limits=> March 26,2018 Pipe#_> 01 Expiration date for these Limits=> December 31,2021 40 CFR#_> N/A The Permittee may discharge from this specific if not applicable put N/A Pipe number according to these specific dates, THE LIMITS ON THIS PAGE ARE,(Check one below). LIMITS for ENTIRE permit period => X effluent limits, and monitoring requirements INTERIM Limits for period# 1 => INTERIM Limits for penod#2 => FINAL Limits Page => Concentration Limits Mass Limits Monitoring Frequency Sample Required Collection Laboratory Monthly Monthly Method Detection Daily Max Average Units Daily Max Average Units By Industry By POTW (C or G) Level 1 Flow MGD Semi-annually Semi-annually 2 BOD Mg/1 See Note Semi-annually Semi-annually C 2 3 TSS See Note Semi-annually Semi-annually C 2 4 Temperature 50 Degree C Semi-annually Semi-annually G 5PH 5-11 Standard Semi-annually Semi-annually G Units OTHER PARAMETERS,Please List Alphabetically 6 Chromium 0 26 Lbs/day Semi-annually Semi-annually C 0.005 mg/1 7 Copper 1.50 Lbs/day Semi-annually Semi-annually C 0.002 mg/1 8 Nickel 0.04 Lbs/day Semi-annually Semi-annually C 0 01 mg/1 9 Zinc 0.50 Lbs/day Semi-annually Semi-annually C 0 01 mg/1 10 11 12 13 NOTE: The BOD and the TSS are to be surcharged if levels exceed 300 mg/1 and 150 mg/1 respectively This permit may be reopened to include BOD limits when the POTW influent exceeds 75 percent of its design capacity. This will be determined by an updated POTW headwork's analysis. Monitoring frequency by industry should be completed within the second Quarter and fourth Quarter of the calendar year. The POTW will monitor within the first Quarter and third Quarter of the calendar year. Other parameters and limits are also subject to change as a result of updated headwork's information. 5 IUP Synopsis A. IUP Basic Information Receiving POTW name POTW NPDES# South Burlington Wastewater Treatment NC0023876 Plant IUP name IUP Number Lemco Mills 0057 IUP Effective date Pipe Numbers,list all regulated pipes March 26, 2018 01 IUP expiration date IUP 40 CFR#,if applicable December 31,2021 N/A B. IUP Survey&Application form Attach a completed copy of the Industrial User Wastewater Survey& Application Form(see appendix 6-A) C. IU Inspection form Attach a copy of an Industrial User Inspection Form (see chapter 7) completed by the Control Authority within the past 12 months. D. RATIONALE FOR LIMITATIONS: As listed on the IUP Limits Page(s), PART I, Section F of the IUP. RATIONALE#1: Review of IU Monitoring Data, with no Over Allocation situation: The following pollutants were assigned numerical limits in this IUP based on a review of monitoring data for the permittee to determine what ranges of concentrations are currently being discharged. To account for sample variability a factor was applied to the monitoring data to determine the permit limit. Permit limits assigned by the Local IUP Control Authority can not results in an Over Allocation situation for any pollutants. Chromium 0.26 lbs/day Copper 1.50 lbs/day Nickel 0.04 lbs/day Zinc 0.50 lbs/day 1 Workbook Name : 2018Update_South_allocation, Worksheet Name: AT Printed 3/23/2018, 12 37 PM Page 1 of 4 Allocation Table Spreadsheet Instructions Headworks last approved 02/02/16 1)Applicable Values should be entered in the Heavy Bordered cells Rest of worksheet is protected,password is Allocation Table updated 03/23/18' p 2)Formulas are discussed in the Comprehensive Guidance,Chapter 6,Section C Permits last modified 03/23/18 3)HWA and AT worksheets in this workbook are linked Pollutant Names,MAHLs,Basis,and Uncontrollable load in this AT worksheet are automatically entered from the HWA spreadsheet This includes pollutant names in columns AT through BK Porw=> South Burlington NPDESt > NC0023786 FLOW BOD TSS Industry Type Renewal Modification Date Permit Limits Permit Limits Permit Limits IUP INDUSTRY NAMES Permit Pipe of Effective Effective Permit Conc Load Conc Load Count _ (please list aipbnbeuciy) number number Industry Date Date Expires MGD gal/day mg/I lbs/da mg/1 lbs/da 1 Alamance Foods 67 0001 Dairy 01/01/17 _ , 12/31/21 _ 2 McComb Industries 71 _ 0001 Textile 01/01/17 , 12/31/21 ; 3 Carolina Biological Sus sly 65 0001 laboratory 01/01/17 12/31/21 4 Carolina Hosiery _ 55 0001 Textile 01/01/17 12/31/21 5 Kayser Roth 52 0001 Textile 07/01/16 01/01/17 06/30/21 6 Labco • 66 0001 . aborator 01/01/17 , 12/31/21 Labcorp 66 0002 t_.aboratory 01/01/17 12/31/21 7 Lemco Hosiery - 57 0001 Textile 01/01/17 03/26/18 12/31/21 8 Pickett Hosiery ! 76 0001 Textile 01/01/17 . 12/31/21 9 _ -. _. Column Totals=> _. __. . 0 0 Basis=> NPDES Design Design MARL from HWA(lbs/day)_> NPDES Permitted Flow=> 12 0000 45036 22518 Uncontrollable Loading(lbs/day)_> 4 9900 12110 9031 Total Allowable for Industry(MAIL)(lbs/day)_> 7 0100 32926 13487 Total Permitted to Industry(lbs/day)_> 0 0 MAIL left(lbs/day)_> #VALUE'_ 32926 13487 Percent Allow Ind (MAIL)still available(%)=> 100 0% 100 0% Percent MAHL still available(%)=> 73 1 % 59 9% 5 Percent MAHL(lbs/day)_> 0 6000 2252 1126 HWA AT Revised November 2005 Workbook Name : 2018Update_South_allocation, Worksheet Name: AT Printed 3/23/2018, 12 37 PM Page 2 of 4 Allocation Table Headworks last approved ' 02/02/16 Allocation Table updated __03/23/18 Permits last modified 03/23118, Porti=>South Burlington NPDES&> NC0023786 Ammonia Arsenic Cadmium Chromium Copper Cyanide Industry Permit Limits Permit Limits Permit Limits Permit Limits Permit Limits Permit Limits _ IUP INDUSTRY NAMES Permit Pipe Conc Load Conc Load Conc Load Conc Load Conc Load Conc. Load Count (please listalphabettcly) number number mg/I lbs/day mg/I lbs/day mg/1 lbs/day mg/1 lbs/day mg/1 lbs/day mg/I lbs/day - 1 Alamance Foods67 0001 _ _ _ _ _ 0.2000 __ 0.4000 2 McComb - _Industries 71 0001 l — I 1.8300 _ _ ' 0 4000 _ _ 3 'Carolina-Biological Supply t 65 0001 i W`�T�' i 0 1000 _ 0 0400 4 CarolinatHosiery 55 0001 + 0 6000 + 0 3000• 5 Kayser Roth 52 0001 ' 8 0000 1 5000 T 6 Labcorp _ 66 0001 01000 0 1000 — 1 66 0002 — 0 1000�i Labcorp 0 1000 7 Lemco Hosiery _, v _ _57._ 0001 0 2600 1 5000 8 Pickett Hosiery` _ _ _I 76 0001 1 0000 ' 0 8200 9 A 10 ,1 I1 Column Totals=> 0 0 0000 r 0.0000 12 1900 5 1600 l 0 00001 Stream Stream AS/Nit/TF AS/Nit/TF Stream Basis=> Design Std Std inhibition inhibition Std MAHL from HWA(lbs/day)_> 3002 40 1 2207 0 4069 24.7867 34 9422 1 0829 Uncontrollable Loading(lbs/day)_> 1082 03 0 1248 0.1248 0 4495 1 1 9477 ,_.(1L2 .1_. 0 Total Allowable for Industry(MAIL)(lbs/day)_> 1920 37 1 0958 0 2820 24.3372 32 9946 0 8748 Total Permitted to Industry(lbs/day)=> 0 00 0 0000 0 0000 12 1900 5 1600 0 0000 MAIL left(lbs/day)=> 1920 37 1 0958 0 2820 12.1472 27 8346 0 8748 Percent Allow Ind.(MAIL)still available(%)_> 100 0% 100 0% 100 0% 49 9% 84 4% 100 0% Percent MAHL still available(%)_> 64 0% 89 8% 69 3% 49 0% 79 7% 80 8% 5 Percent MAHL(lbs/day)_> 150 12 0 0610 0 0203 1 2393 1 7471 0 0541 HWA AT Revised November 2005 Workbook Name : 2018Update_South_allocation, Worksheet Name: AT Printed 3/23/2018, 12 37 PM Page 3 of 4 Allocation Table Headworks last approved '-02/02/16 _ Allocation Table updated 03/23/18.' Permits last modified 03/23/18; Poiw=> South Burlington NPDESt > NC0023786 Lead Mercury Molybdenum Nickel Selenium Industry Permit Limits Permit Limits Permit Limits Permit Limits Permit Limits IUP INDUSTRY NAMES Permit Pipe Conc Load Conc Load Conc Load Conc Load Conc Load Count (please ltstalphabehcly) number number mg/1 lbs/day mg/1 lbs/day mg/1 lbs/day mg/1 lbs/day mg/1 lbs/day 1 Alamance Foods _ _ 67 _- 0001 �_ . 0.0500 i 2 (McComb Industries 71 : 0001 . 0 1400__ 4 3 Carolina Biological Supply _v 65 0001 -_ j� 0 0100 l 4 Carolina_Hosie_ry 55 ; 0001 ' l 0 1000 t 5 Kayser Roth 52 0001 - 0 8000—" 6 Labcorp _ 66 4 0001 0.001101 0 0150 i ;Labcorp - 66 0002 } 0 00040( 0.0150 1 7 Lemco Hosiery 57 ; 0001 • f 0 0400 8 Pickett Hosiery 76 0001 _ - 0 0800 Column Totals=> 0 0000 0 001500 0 0000 1 2500 0 00001 Stream Sludge Stream Stream Basis=> Std Stream Std Ceiling Std Std MAHL from HWA(lbs/day)=> 4.3037 0 063437 1 6953 4 7480, 0 6714 Uncontrollable Loading(lbs/day)=> 0 1540 0 012485 0 0541 0.5036, 130___0541 Total Allowable for Industry(MAIL)(lbs/day)_> 4.1497 0 050952 1 6412 4.2445 I 1 :1 Total Permitted to Industry(lbs/day)_> 0 0000 0 001500 0 0000 1 2500 0 0000 MAIL left(lbs/day)=> 4.1497 0.049452 1 6412 2 9945 0 6173 Percent Allow Ind (MAIL)still available(%)=> 100 0% 97 1%0 100 0% 70 5% 100 0% Percent MAHL still available(%)_> 96 4% 78 0% 96 8% 63 1% 91 9% 5 Percent MAHL(lbs/day)=> 0 2152 0 003172 0 0848, 0 2374 0.0336 HWA AT Revised November 2005 Workbook Name : 2018Update_South_allocation, Worksheet Name: AT Printed 3/23/2018, 12 37 PM Page 4 of 4 . Allocation Table Headworks last approved i 02/02/16 Allocation Table updated y 03/23/18. Permits last modified ; 03/23/18 POTw=> South Burlington NPDES#✓=> NC0023786 Silver Zinc Total Nitrogen Total Phos. Aluminum Industry Permit Limits Permit Limits Permit Limits Permit Limits Permit Limits IUP INDUSTRY NAMES Permit Pipe Conc Load Conc Load Cone Load Cone Load Conc. Load Count (please ltstalphabcttcly) number number mg/I lbs/day mg/I lbs/day mg/1 lbs/day mg/1 lbs/day mg/I lbs/day 1 Alamance Foods 67 t 0001 1.50001 __ 2 McComb Industries 71 . 0001 t 0 8000 l !=!!..43 Carolina Biological Supply 65 0001 ' 1 0000 .. 4 1Carolina Hosiery �� _55 , 0001 1 d 0 6600 ) , 5 Kayser Roth 52 0001 i 1 2 6000W ___ 6 Labcorp 1 ` 66 0001 i _4_.. _i 0 2500 Labcorp 66 0002 0 2500 7 Lemco Hosiery 57 ; 0001 i 0 50001-11 i 8 Pickett Hosiery 76 0001 11 0 4000 9 LIMO Io [ ( - l I Column Totals=> y 0 0000, 7 9600 0 00 0 00 0 0000 AS/Nit/TF AS/Nit/TF Basis=> inhibition inhibition NPDES MAHL from HWA(lbs/day)_> 15 9242 74 9374 546 56 Uncontrollable Loading(lbs/day)=> 0 2081 7 9404 188 78 36 5893 Total Allowable for Industry(MAIL)(lbs/day)_> 15 7161 66 9969 357 78 Total Permitted to Industry(lbs/day)_> 0.0000 7 9600 0 00 0 00 0 0000 MAIL left(lbs/day)=> 15 7161 59.0369 357 78 Percent Allow Ind (MAIL)still available(%)_> 100 0% 88 1% ####### 100 0% ####### Percent MAHL still available(%)_> 98.7% 78.8% ####### 65.5% ####### 5 Percent MARL(lbs/day)_> 0 7962 3 7469 27 3280 HWA AT Revised November 2005 Roger Page Lemco Mills Inc. 766 Koury Drive Burlington, NC 27215 March 22, 2018 City of Burlington Water Resources Subject: Response to Notice of Violation Lemco Mills, Inc. Pretreatment Permit#0057 Dear City of Burlington. We received a Notice of Violation indicating our plant's water sample revealed 0.140 lbs/day copper concentration compared to our permit level of 0.10 lbs/day. On 1/25/18,the day of water testing, our plant was not quite full production. The dye house ran a typical day Four 50 lb tubs out of 13 tubs (20%of total poundage capacity) ran premetallized dye formulas. Our two larger 200 lb.tubs were not scheduled. Our production runs are trending to smaller tub sizes and a larger percentage of current production is requiring premetallized dyestuffs to minimize bleeding of color We may need to consider an increase in Copper permit level if this trend continues. I have contacted Pace Analytical to perform two additional analyses. Sincerely, Roger Page 336-226-5548