WQ0004639_Final Permit_19910423

State of North Carolina
Department of Environment, Health and Natural Resources
Division of Environmental Management
512 North Salisbury Street • Raleigh, North Carolina 27626-0535
James G. Martin, Governor George T. Everett, Ph.D.
William W. Cobey, Jr., Secretary Director
April 23, 1991
Mr. Thomas Katsamas, Director of Facility Engineering
Sara Lee Knit Products
700 Stratford Road
Winston-Salem NC 27103 ,
Subject: Permit No. WQ0004639
Sara Lee Knit Products Stratford Road Plant
Groundwater Remediation
Forsyth County
Dear Mr. Katsamas:
In accordance with your application received January 22, 1991, we are forwarding
herewith Permit No. WQ0004639, dated April 23, 1991, to Sara Lee Knit Products for the
construction and operation of the subject groundwater rernediation system.
- This permit shall be effective from the date of issuance until March 31, 1996, and shall be
subject to the conditions and limitations as specified therein. Please pay particular attention to the
monitoring requirements in this permit. Failure to establish an adequate system for collecting and
maintaining the required operational information will result in future compliance problems.
If any parts, requirements, or limitations contained in this permit are unacceptable to you,
you have the right to request an adjudicatory hearing upon written request within 30 days
following receipt of this permit. This request must be in the form of a written petition, conforming
to Chapter -150B of North Carolina General Statutes, and filed with the Office of Administrative
Hearings, P.O. Box 11666, Raleigh, NC 27604. Unless such demands are made this permit shall
be final and binding.
One set of approved plans and specifications is being forwarded to you. • If you need
additional information concerning this matter, please contact Mr. Lindsay L. Mize at 919/
733-5083.
cc:
Sincerely,
George
Forsyth County Health Department6 T. E nett
Winston-Salem Regional Office
Groundwater Section
Aquaterra, Incorporated
Training and Certification
Pollution Prevention Pays
P.O. Box 29535, Raleigh, North Carolina 27626-0535 Telephone [phone]
An Equal Opportunity Affirmative Action Employer

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NORTH CAROLINA
ENVIRONMENTAL MANAGEMENT COMMISSION
DEPARTMENT OF ENVIRONMENT, HEALTH AND NATURAL RESOURCES
RALEIGH
INFILTRATION GALLERY PERMIT
In accordance with the provisions of Article 21 of Chapter 143, General Statutes of North
Carolina as amended, and other applicable Laws, Rules, and Regulations
PERMISSION IS HEREB'} GRANTED TO
Sara Lee Knit Products
Forsyth County
FOR THE`
construction and operation of a 360 GPD groundwaterremediaAon system which consists of a 5
GPM recovery pump, a 50 gallon surge tank with metering pump, two (2) 170 pound activated
carbon canisters arranged in series, and an infiltration gallery - seven (7) feet wide, six (6) feet
deep, and forty (40) feet long to serve Sara Lee Knit Products - Stratford Road, Winston-Salem
Plant with no discharge to the surface waters, pursuant to the application received January 22,
1991 and in conformity with the project plan, specifications, and other supporting data
subsequently filed and approved by the Department of Environment, Health and Natural Resources
and considered a part of this permit.
This permit shall be effective from the date of issuance until March 31, 1996, and shall be
subject to the following specified conditions and lin-.dtations:
I. PERFORMANCE STANDARDS
1. Upon completion of construction and prior to operation of this permitted facility, a
certification must be received from a professional engineer certifying that the
permitted facility has been installed in accordance with this permit and the approved
plans and specifications. Mail the Certification to the Permits and Engineering Unit,
P.O. Box 29535, Raleigh, NC 27626-0535.
2. The Winston-Salem Regional Office, phone no. 919I761-2351 shall be notified
at least two (2) weeks in advance of operation of the installed facilities so
that an in -place inspection can be made. Such notification to the regional supervisor
shall be made during the normal office hours from 8:00 a.m. until 5:00 p.m. on
Monday through Friday, excluding State Holidays.
3. This permit shall become voidable if the soils fail to adequately absorb the wastes
and may be rescinded unless the facilities are installed, maintained, and operated in a
manner which will protect the assigned water quality standards of the surface waters
and ground waters.

4. In the event that the facilities fail to perform satisfactorily, including the creation of
nuisance conditions, the Permittee shall take immediate corrective action, including
those as may be required by this Division, such as the construction of additional or
replacement treatment or disposal facilities.
5. The issuance of this permit shall not relieve the Permittee of the responsibility for
damages to surface or groundwaters resulting from the operation of this facility.
6. Any sludge generated from these treatment facilities must be disposed of in
accordance with General Statute 143-215.1 and in a manner approved by the North
Carolina Division of Environmental Management.
7. Diversion or bypassing of the untreated groundwater from the treatment facilities is
prohibited.
II. OPERAIIQN AND MAINTENANCE REQUIREMENTS
1. The facilities shall be properly maintaine# and operated at all times.
2. Upon classification of the facility by the Certification Commission, the Permittee
shall employ a certified wastewater treatment plant operator to be in responsible
charge of the wastewater treatment faciiiti�; s. The operator must hold a certificate of
the type and grade at least equivalent to the classification assigned to the wastewater
treatment facilities by the Certification Commission. Once the facility is classified,
the Permittee must submit a letter to the Certification Commission which designates
the operator in responsible charge within thirty days after the wastewater treatment
facilities are 50% complete.
3. The facilities shall be effectively maintained and operated as a non -discharge system
to prevent the discharge -of any wastewater resulting from the operation of this
facility.
4. The facilities shall be effectively weather -proofed to prevent freezing and failure of
the system.
IIL MONITORINQ AND REPORTING REQUIREMENTS
1. Any monitoring deemed necessary by the Division of Environmental Management to
insure surface and ground water protection will be established and an acceptable
sampling reporting schedule shall be followed.
2. Noncompliance Notification:
The Permittee shall report by telephone to the Winston-Salem Regional Office,
telephone no. 919/761-2351, as soon as possible, but in no case more than 24 hours
or on the next working day following the occurrence or first knowledge of the
occurrence of any of the following:
a. Any occurrence at the wastewater treatment facility which results in the
treatment of significant amounts of wastes which are abnormal in quantity or
characteristic, such as the dumping of the contents of a basin or tank; the
known passage of a slug of hazardous substance through the facility; or any
other unusual circumstances.

b. Any process unit failure, due to known or unknown reasons, that render the
facility incapable of adequate wastewater treatment such as mechanical or
electrical failures of pumps, aerators, compressors, etc.
C. Any failure of a pumping station, sewer line, or treatment facility resulting in
a by-pass directly to receiving waters without treatment of all or any portion
of the influent to such station or facility.
d. Any time that self -monitoring information indicates that the facility is not in
compliance with its permit limitations.
Persons reporting such occurrences by telephone shall also file a written report in
letter form within 15 days following first knowledge of the occurrence. This report
must outline the actions taken or proposed to be taken to ensure that the problem
does not recur.
IV. GROUNDWATER REDUUMEEMENTS
r,
u
l . The influent and effluent from the treatment system shall be sampled once every
month for the first three (3) months and monthly thereafter for the parameters
specified below:
i {
Semi -Volatile Organic Compounds using US EPA l 4ethod 8270
TOC
PH
The results of the sampling and analysis shall be sent to the Groundwater Section in
the Winston-Salem Regional Office, within 30 days of sample collection.
2. - The groundwater recovery treatment and disposal system shall be inspected weekly.
If it is determined that the system is malfunctioning, all repairs should be made as
soon as possible and reported to the Winston-Salem Regional Office.
3. Any .groundwater quality monitoring as deemed necessary by the Division of
Environmental Management shall be provided.
V. I
l . Adequate inspection, maintenance and cleaning shall be provided by the Permittee to
insure proper operation of the subject facilities.
2. The Permittee or his designee shall inspect the groundwater recovery and treatment
facilities to prevent malfunctions and deterioration, operator errors and discharges
which may cause or lead to the release of wastes to the environment, a threat to
human health, or a nuisance. The Permittee shall keep an inspection log or summary
including at least the date and time of inspection, observations made, and any
maintenance, repairs, or corrective actions taken by the Permittee. This log of
inspections shall be maintained by the Permittee for a period of three years from the
date of the inspection and shall be made available upon request to the Division of
Environmental Management or other permitting authority.
3

3. Any duly authorized officer, employee, or representative of the Division of
Environmental Management may, upon presentation of credentials, enter and inspect
any property, premises or place on or related to the disposal site and facility at any
reasonable time for the purpose of determining compliance with this permit; may
inspect or copy any records that must be kept under the terms and conditions of this
permit; or may obtain samples of groundwater, surface water, or leachate.
V1. GENERAL CONDITTQNS
This permit shall become voidable unless the facilities are constructed in accordance
with the conditions of this permit, the approved plans, specifications and other
supporting data.
2. This permit is effective only with respect to the nature and volume of wastes
described in the application and other supporting data.
3. This permit is not transferable. In the event there is a desire for the facilities to
change ownership, or there is a name Change of the Permittee, a formal permit
request must be submitted to the Division of Environmental Management
accompanied by an application fee, documentation from the parties involved, and
other supporting materials as may be appropriate. The approval of this request will
be considered on its merits and may or maynot be approved.
4. The Permittee shall obtain a well construction permit from the Winston-Salem
Regional Office prior to construction of the recovery wells.
5. Prior to a transfer of this land to a new owner, a notice shall be given to the new
owner that gives full details of the materials applied or incorporated at this site. -
6. A set of approved plans and specifications for the subject project must be retained
by the Permittee for the life of this project.
7. Failure to abide by the conditions and limitations contained in this permit may subject
the Permittee to an enforcement action by the Division of Environmental
Management in accordance with North Carolina General Statute 143-215.6.
8. The annual administering and compliance fee must be paid by the Permittee within
thirty (30) days after being billed by the Division. Failure to pay the fee accordingly
may cause the Division to initiate action to revoke this permit as specified by 15
NCAC 2H .0205 (c)(4).
9. The issuance of this permit does not preclude the Permittee from complying with any
and all statutes, rules, regulations, or ordinances which may be imposed by other
government agencies (local, state, and federal) which have jurisdiction.
10. The Permittee, at least six (6) months prior to the expiration of this permit, shall
request its extension. Upon receipt of the request, the Commission will review the
adequacy of the facilities described therein, and if warranted, will extend the permit
for such period of time and under such conditions and limitations as it may deem
appropriate.
CI

Permit issued this the 23rd day of April, 1991
NORTH CAROLINA ENVIRONMENTAL MANAGEMENT COMMISSION
Oeorge T. Everett, Director
Division of Environm tal M a meat
By Authority of the Environme tal Management Commission
Permit No. WQ0004639
April 23,1991
Enmineer's Certification
I, , as a duly registered Professional Engineer in the State of North
Carolina, having been authorized to observe (periodically, weekly, full time) the construction of the
project, , _ for the
Project Name Location
Permittee hereby state that, to the best of my abilities, due care and diligence was used in the
observation of the construction such that the constriction was observed to be built within substantial
compliance and intent of the approved plans and specifications.
Signature Registration No.
Date
5

5
(MISCELLANEOIIS UNITS CONTINUED) POINTS
(e) Holding Pond for Effluent Flow Equalization and/or
Stage Discharge . . . . . . . . . . _ . . . . . _ 5
(d) Effluent Pumps . . . . . . . . . . . . . .
SSe) In -Plant Pumps (including air lifts).
(f) Stand -By Power Supply . . . . . . . . . . . . . . . 3
(((9) Thermal Pollution Control Device 3
(h) Treatment Processes for Removal of Metal or Cyanide and
other Toxic Materials . . . . . . . . . . . . . . . 30
Total Points _1L
CLASSIFICATION
Class 1 5 25 Points
as . . . . . . . . . . . . 26 - 0 nts
Class III . . . . . . . . . . . . . . . 51 - 65 Points
Class Iv . . . . . . . . . . . . . . 1 66 - Up Points
Facilities having a rating of one through four points, inclusive,
do not require a certified operator. Classification of all other
facilities requires a comparable grade operator in responsible charse, .
North Caroiina
Division of Environmental Management
Checklist of Facility Components
To be Used In Determing Facility Classification
i
All Information will be printed:
Name of PIantgAt A I e e kh,' j /,ryuC �S
County f h
Owner or Contact Person fi d a S I q
Mailing Address .700 N4Y'0A!JRrr d !�;�<�o� S,o%.� e��3
Street or x e ep one
—mown or t
Permit Number Information
Construction Status
HPDES Permit No. Please Check:
Existing Facility
Date Issued Upgraded Facility
New Facility s✓�
State Permit No. &Od{� f1�i3y _ If Upgraded or Hewcility, Give:
50% Completion Date
Date Issued 0�; /Q��. _ 100%Completion Date �/
Rated by `{ycfs T {%j, �-[ I Office C ^�f? f r ( Date / 16
Operator in Responsible Charge Grade
Design Flow of Plant in GPO 3 �Plant Class
ITEM
POINTS
(1) PRETREATMENT UNITS (see definition No. 34) .
2
2) DESIGN FLOW OF PLANT IN GPD (not applicable to non
contaminated cooling waters and non -discharging systems
0 -- 20.000 . . . . . . . . . . . . . . . . .
. 1
20.001 -- 50,000 . . . . . . . . . . . . . . . .
. 2
50,001 -- 100,000 . . . . . . . . . . . . . . . . .
. 3
100,001 -- 250,000 . . . . . . . . . . . . . . . .
. 4
250,001 -- 500.000 . . . . . . . . . . . . . . . . .
. 5
5001D01 -- 110DO.000 . . . . . . . . . . . . . . . . .
. 8
1,OOD,001 2,000,000
10
2,000,001 (and up) - rate 1 point'additionai for eaW 200,000
GAD capacity up to a mmaximuo of . .
. 30
Design Flow (GPD);
(3) PRELIMINARY UNITS (see definition . . . . . . . ..
(a) Influent Pumps (including air lift) .
Q
(b) Bar Screens . . . . . . . . . . . . . . .
1
or
(c) Mechanical Screens, Static Screens or Comminuting
Devices . . . . . . . . . . . . . . . . . . .
2
(d) Grit Removal or . . . . . . . . .
I
(e) Mechanical or Aerated Grit Removal . . . . . . . . .
2
(f) Flow Measuring Device or . . . . . . . . . . . . . .
1
(g) Instrunented Flow Measurement . . . . . . . . . . . .
2
-4- Effective
4111$7 -1-

(4)
(5)
(5)
ITEM
POINTS
(h)
Preaeration or Equalization . . . . . .
(1)
Grease or Oil Separators -- Gravity . . .
Z
Mechanical. . .�
Aerated . . . .
5 E
(J)
Chemical Conditioning . . . . . . . . . . . . . . .
5
PRIMARY
TREATMENT UNITS
(a)
Septic Tank (see definition No. 44) . . . . . . . .
2
(b)
Imhoff Tank
3
(c)
Primary Clarifiers (including sludge air lifts)
5
d)
Settling Ponds or Settling Tanks for inorganic Non -
Toxic Materials Involving a Discharge to the Surface
waters (sand, gravel, stone, and other mining operations
except recreational activities such as gem or gold
mining) . . . . . . . . . . . . . . . ..
10
SECONDARY TREATMENT UNITS
(a)
Carbonaceous Stage
(1) Aeration - High Purity Oxygen System . . . .
20
Diffused Air System . . . .
10
Mechanical Air System (fixed, floating or rotor)
8
Separate Sludge Reaeration . . . . . . . . .
3
(1i} Trickling Filter - High Rate . . . . . . . .
7
Standard Rate . . . . . .
5
Packed Tourer . . . . . . .
5
(lii) Aerated Lagoons . . . . . . . . . . .'
10
(iv) Rotating Biological Contactors (blodisc). . ,
10
(v) Sand Filters (intermittent biological) . . .
2
(vfjj Stabilization Lagoons
5
(vii} Clarifier (including sludge air lifts).
5
(b)
Nitrogenous Stage
(i) Aeration - High Purity Oxygen System.
20
Diffused Air Systems. . .
10
Mechanical Air System (fixed, floating, or rotor)8
Separate Sludge Reaeration . . . . . . . . .
3
(ii) Trickling Filter - High Rate . . . . . . . .
7
Standard Rate . . . . . .
5
Packed Tower. . .
5
.(Eli)
Rotating Biological Contactors (biodisc) . .
10
(iv) Sand Filter (intermittent biological), , , ,
2
(v) Clarifier (including sludge air lifts) . . .
5
TERTIARY
OR ADVANCED TREATMENT UNITS
(a)
Activated Carbon Beds - without Carbon regeneration
a
With Carbon regeneration.
15
(b)
Powdered or Granular Activated Carbon Feed-'4lithaut
Carbon regeneration .
With Carbon regeneration,
I
(c)
Ammonia Stripping . . . . . . . . . . . . . .
18
(d)
Chemical Additions . . . . . . .
5
(e)
0rnitrlficatlon Process (separate process). . . .
10
(f)
Electrodialysis . . . . . . . . . . . . . . . . .
5
(g)
Foam Separation . . . . . . . . . . . . . . . . .
5
(h)
]on Exchange . . . . . . . . . . . . . . . . . . .
5 ;
spa
i' fib`' ` f 1
ITEM
POINTS
(1)
Land Application (see definition No. 23b)
5
(not applicable for facilities under 10(a) .
(j )
M1 croscreens . . . . . . . . . . . . . . ... . . .
5
(k)
Phosphorus Removal . . . . . . . . . . . . . . . .
20
(1)
Polishing Ponds- 'Without aeration . . . . . . . .
2
With aeration . . . . . . . . . .
5
(m)
Post Aeration - Cascade . . . . . . .
0
Diffused or Mechanical
5
(n)
Pre -Package Unit for Removal of Oil and Grease
30
(o)
Reverse Osmosis . . . . . . . ..
5
(p)
Sand or Mixed -Media Filters -- Low Rate . . . . ..
2 �q
High Rate
S #
(7)
SLUDGE TREATMENT
t'
(a)
Sludge Digestion Tank -- Heated . . . . . . . . . .
10
: Aerobic . . . . . . . . .
5
Unheated . . . .
3
(b)
Sludge Stabilization (chemical or thermal) . . . .
10
(c)
Sludge Drying Beds . . . . . . . . . . . . . . . .
2
(d)
Sludge Elutrlation
5
Sludge Conditioner (chemica) or thermal)
5
ie)
f)
Sludge Thickener
2
(g)
Sludge Gas Utilization (lnciuding gas storage). . .
2
{h)
Sludge Holding Tank -- Aerated
5
Non -aerated . . . . . .
2
(I)
Sludge Incinerator (not Including activated carbon
regeneration) . . . . . . .
10
-
(Jr"$acuiim
Filter, Centrifuge or Filter Press . . . .
10
- GS)
SLUDGE DISPOSAL (including incinerated ash)
(a)
Lagoons
2
(b)
Land Application (surface and subsurface) -(see def.
23a ) . . . . . . . . . . . . .
10
(c)
Landfilled (burial) . . . . . . . . . . . . . . .
5
(9)
OISINFECTWN
Pre . . . . . ... . . . . . . . . . . . . . . . .
1
�a)
b)
intermediate . . . . . . . . . . . . . . . . . .
2
(c)
-Post . . . . . . . . . . . . . . . . . .
3
(d)
Dechlorination. . . . . . . . . . . .
5
(e)
Chlorine or Ozone Generation . . . . . . . . . .
5
(f)
Radiation . . . . . . . . . . . . . . . . .
3
(10)
MISCELLANEOOS
UNITS
(a)
llolding Ponds or Ikrlding Tanks for Inorganic, Nan -toxic
Materials with no Discharge to the Surface staters
2
(Sludge handling facilities for water purification
plants, sand, gravel, crushed stone and other similar
operations --see definition No. 10)
(b)
Holding Ponds or liolding Tanks for Organic or Toxic
Material', with ivi 01-,charge to thr surface tratert
4
(Any pump, valve, or other mechanical control subject
to failure creating a potential for bypass or discharge
from the holding ponds or tanks will necessitate a
minimum classification of Class ] requiring a certified
operator).
-3-