WQ0000026_Final Permit_19930728

State of North Carolina
Department of Environment,
Health and Natural Resources
Division of Environmental Management
James B. Hunt, Jr., Governor
Jonathan B. Howes, Secretary
A. Preston Howard, Jr., P.E., Director
July 28, 1993
Paul G. Brown, President
Clark Stone Company, Inc.
Route 1, Box 610
Zionville, North Carolina 28698
Dear Mr. Brown:
1:3EHNF1
Subject: Permit No. WQ0000026
Clark Stone Company, Inc.
Wastewater Recycle System
Avery County
In accordance with your renewal request received February 12, 1993, we are forwarding herewith
Permit No. WQ0000026, dated July 28, 1993, to Clark Stone Company, Inc. for the continued operation
of the subject wastewater recycle system.
This permit shall be effective from the date of issuance until June 30, 1998, shall void Permit No.
WQ0000026 'issued October 11, 1988 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. Drawer 27447,
Raleigh, NC 27611-7447. Unless such demands are made this permit shall be final and binding.
If you need additional information concerning this matter, please contact Mr. Michael D. Allen at
[phone].
Sincerely,
A. Prest Howard, Jr., P.E.
Director
cc: Avery County Health Department
Asheville Regional Office
Facilities Assessment Unit
Training and Certification Unit
P.O. Box 29535, Raleigh, North Carolina 27626-0535 Telephone [phone] FAX [phone]
An Equal Opportunity Affirmative Action Employer 50% recycled/ 10% post -consumer paper

NORTH CAROLINA
ENVIRONMENTAL MANAGEMENT COMMISSION
DEPARTMENT OF ENVIRONMENT, HEALTH AND NATURAL RESOURCES
RALEIGH
RECYCLE SYSTEM 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 HEREBY GRANTED TO
Clark Stone Company, Inc.
Avery County
FOR THE
continued operation of a 4,800 GPD wastewater recycle system consisting of a 105 ft. by 96 ft. by 15 ft.
supply pond, a 200 GPM supply pump, a screening device, two (2) settling ponds; 100 ft. by 180 ft. by
15 ft. and 120 ft. by 130 ft. by 15 ft. connected in series, a 100 GPM recirculation pump and all other
piping and appurtenances to serve Clark Stone Company with no discharge of wastes to the surface
waters, pursuant to the renewal request received February 12, 1993, and in conformity with the prc jec,
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 June 30, 1998, shall void Permit No.
WQ0000026 issued October 11, 1988 and shall be subject to the following specified conditions and
limitations:
1. 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.
The facilities shall be properly maintained and operated at all times.
4. 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 the request will be considered on its merits and may or may
not be approved.
5. 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
wastewater treatment or disposal facilities.

6. The 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. 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.
8. 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.
11. Diversion or bypassing of untreated wastewater from the treatment facilities is prohibited.
12. Freeboard in the settling ponds shall not be less than two (2) feet at any time.
13. Any monitoring deemed necessary by the Division of Environmental Management to insure
surface and groundwater protection will be established and an acceptable sampling
reporting schedule shall be followed.
14. Adequate inspection, maintenance, and cleaning shall be provided by the Permittee to
insure proper operation of the subject facilities.
15. The Permittee or his designee shall inspect the wastewater recycle 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.
16. 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 recycle system 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.
17. 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).
18. 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 143-215.6A to 143-215.6C.
19. 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.
2

20. Noncompliance Notification:
The Permittee shall report by telephone to the Asheville Regional Office, telephone number
[phone] 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 tht
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.
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.
21. Upon classification of the facility by the Certification Commission, the Permittee shall
employ a certified wastewater treatment plant operator to be in responsible charge (ORC) of
the wastewater treatment facilities. The operator must hold a certificate of the type and
grade at least equivalent to or greater than the classification assigned to the wastewatez
treatment facilities by the Certification Commission. The Permittee must also employ a
certified back-up operator of the appropriate type and grade to comply with the conditions
of Title 15A, Chapter 8A, .0202. The ORC of the facility must visit each Class I facility at
least weekly and each Class II, 111, and IV facility at least daily, excluding weekends and
holidays, and must properly manage and document daily operation and maintenance of the
facility and must comply with all other conditions of Title 15A, Chapter 8A,.0202.
22. 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.
Permit issued this the 28th day of July, 1993
NORTH CAROLINA ENVIRONMENTAL MANAGEMENT COMMISSION
6 , '0. /t,
A. Preston oward, Jr., P.11., Director
Division of Environmental Management
By Authority of the Environmental Management Commission
Permit No. WQ0000026
3

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Name of Plant.-
Owner
lant:
Owner or Contact Person:
Mailing Address: R4-
2i��zL���lx-"
N
County: A v Telephone:
NPDES Permit No. NCOO Nondisc. Per. No.&16U_)?)VeV
IssueDate: Expiration Date: Y
Existing Facility L-- New Facility
Rated By: Date:
Reviewed '(Train. & Cert.) Reg. Office_ Q
Reviewed (Train. & Cert.) Central Office
ORC Grade
Plant Class: (circle ane) 1 11 111 IV. Total Point .;:.
rTEM POINTS
(5) SECONDARY TREATMENT UNITS
(a) Carbonaceous Stage `
(1)
Industrial Pretreatment Units and/or
(i)Aeration - High Purity Oxygen System . _ _ ..
20
Industrial Pretreatment Program
Diffused fW System ...........
10
see definition No, 33
{ )
4
Mechanical Air System (fixed,
(2)
122 -SIGN FLOW OF PLANT W GPD
lioaling or rota .......
(not applicable to non -contaminated tooting waters, sludge
Separate Sludge Reaeration .....
3
handling facilities for water purification plants, totally
(ii) Trickling Filter
closed cycle systems (del. -No. 11), and facilities
High Rate . .....
7
consisting only of Item (4) (d) or Items (4) (d) and {11) (d))
Standard Rale. ............. . .
5
0 -- 20,000. . ... . ....................
1
Packed Tower:::....... .
..
5
20,001 -- 50,000 ..........................
2
(iii) Biological- Aerated .Filter or Aerated '
50,001 -- 100,000 ................. i........
3
Biological Filter .......... _ ........ _ ..
0
100,D01 - 250,000 ..........................
4
(iv) Aerated Lagoons . ... . - •-
i 0
250,001 - 500,000 ..... . .............. . . .
5
500,001-1,0D0,D00 ..........................
8
(v) Rotating Biological Contactors...... _ _ ...
10
.
1,000,001 - 2,000,000 ........................
10
2,000,001 (and up) - rate 1 point additional for each
(vi) Sand Filters -
200,000 gpd capacity up to a
intemillenl biological .....
-2
maximum o 30 ''
f
recirculating biological .':". "..
3
Design Row (gpd)
(vtt Stabilization Lagoons .. .....
5
(3)
PRELIMINARY UNITS (see definition no. 32)
(viii)clarifier
5
(a) BarScreens. ..................... ........
1
(ix) Single stage system for combined
or
carbonaceous removal of Bob and
(b) Mechanical Screens, Static Screens or
nitrogenous removal by nitrification
Comminuting Devices ........................
2
(see der. No,' 12) (Poials for this item
(c) Grit Removal ...............................
1
have to be in addition fo' items (5) (a)
o r
(i) through (5) (a) (viu)' ! . �::: ':.".:........
8
(d) Mechanical or Aerated Grit Removal ....... _ . _ :
2
(x) Nutrient additions to enhance SOD
(e) Flow Measuring Device .......................
1
removal ...........'.' :... .... _ .. - — _ ..
5
or I
(xi) Biological Culture ('Super Bugs') addition
(f) Instrumented Flow Measurement .. . ...........
2r
to enhance 'organic compound' removal ...
(g) Preaerallon................................
2
(b)M1 Nitrogenous Stage
(i) Aeration = High Purity Oxygen System _ . , .
20
(h) Influent Row•Equaffzalion ...... . ...... . . ....
2
Dilfused Air System ...........
10
(i) Grease or Oil Separators - Gravity ..........
2
Mechanical Air System (fixed, '
Mechanical ..........
3
floaling or rotor) ...... ......
8
Dissolved Air Flotalion.
8
'' Separate Sludge Reaeralion _ ....
3
0) Prechlorinar*n ...... . .......................
5
(if) Trickling Filler - - '
High Rale . . ............
7
(4)
PRIMARY TREATMENT UNITS
Standard Rale ............
5
(a) Septic Tank (see definition no. 43) .... . .. . ......
2
Packed Tower............
5
(b) Imhoff Tank ... . ....... . .... . . . ...............
5
(iii) Biological Aerated Filter or Aerated
(c) Primary Clarifiers .. . .........................
5
Biological Filler ... _ ................... _
D
(d) Settling Ponds or Settling Tanks for Inorganic
(iv) Rotating Biological Contactors .... _ .......
10
Non•loxic Materials (sludge handling facilities
(v) Sand Filter -
for water purification plants, sand. gravel,
intermittent biological ... .
2
stone, and other mining operations except
recirculating biological .. . . . .. .
3
creational activities such as gem or gold
(vi) Ctarilier .... . ... . ........ . . . • • • .. - . • • . •
5
mining) ......................................
2

,�� c rttrvir�.Al AUU1l ILIN SYSTEM (S) (See definition NO 9)
(al Activatco w,aroons ueas (not applicable to chemical additions rated as ileml_�
without carbon regeneration .............. 5 (3) Q. (5) (a) (xi). (6) (a), (6) (b), (7) (b), (7) (e),
with carbon regeneration .................... is
(b) Powdered or Granular Activated Carbon Feed - (9) (a), (9) (b), or (9) (c) 5 points each: List:
5
Without carbon regeneration ................. 5
5
With carbon regeneration ................... 1 5 5
rc) Air Stripping ............................5 5
lDenilriGealion Process (separate process) . - . .. 10
Electrodialysis .............................. 5 (11) MISCELLANEOUS UNITS
(r) Foam Separation ............................. 5 (a) Holding Ponds, Holding Tanks or Settling Ponds
(g) Ion Exchange ................................ 5 for Organic or Toxic Materials including wastes
(h) Land Application of Treated Effluent from mining operations containing nitrogen and/or
(see definition no. 22b) (not applicable for phosphorous compounds in amounts significantly
sand, gravel, stone and other similar mining greater than is common for domestic wastewater .......... 4
operations) (b) Effluent Flow Equalization (not applicable to storage
(i) on agdoillurally managed sites (See def. basins which are inherent in land application systems). 2
No. 4) ................................... 10 (c) Stage Discharge (not applicable to storage basins
(ii) by high rale inGflration on non-agricuttu rally inherent in land application systems ....................................... 5
managed sites (includes rotary distributors (d) PunVs ___ 3
and similar fixed nozzle systems) .......... - 4 (e) Stand -By Power Supply_ 3
(iii) by subsurface disposal (includes low pressure (f) Thermal Pollution Control Device:....-,- ...„. _ .......... 3
pipe systems and gravity systems except at
plants consisting of septic lank and nitrifica-
tion lines only) ............................ 4 TOTAL POINTS
nNiivasrreens.......--....................... 5
(j) Phosphorus Remofal by Biological Processes CLASSIFICATION
(See del. No. 26) 20
(k) Polishing Ponds - without aeration ....... 2 Class L. S.- '25 Points
with aeration .......... 5 Class It. 26- 60 Points
(n Posl Aeration - cascade .............. 0 Class Ill. _ _.I 51- 65 Points
diffused or mechanical ... 5 Class TV. _ „ 66- Up Points
(m) Reverse Osmosis................................ 5
(n) Sand or Mixed -Media Filters -low rate ..... _ _ .... 2 Ldc
ies having a rating of one through four points, Inclusive,
high rate .......... 5 t require a certified operator. Classification of all other(o) Treatment processes for removal of metal or es requires a comparable grade operator in responsiblecyanide ............ ....................... 15 e.
Treatment processes .for removal of toxic
materials other than metal or cyanide ......... 15 ies having an activated sludge process will be assigned
a minimum classification of Class Il.
SL, E TREATMENT Facilities having treatment processes for the removal of metal
(a) Sludge Digestion Tank - Heated ............... 1 0 or cyanide will be assigned a minimum classification of Class 11.
Aerobic .... _ ......... 5
Unhealed ............. 3 Facilities having treatment processes for the biological removal
(b) Sludge Stabilization (chemical or thermal) .. _ .... 5 of phosphorus will be assigned a minimum classification of Class
(c) Sludge Drying Beds - Gravity...... . .. . . . . . - - 2
Vacuum Assisted ....... S
(d) Sludge Elutriation ............................. 5 In -plant processes and related control equipment which are an
e Sludge Conditioner chemical or thermal ...... 5
() dg ( ) - integral part of industrial production shaft not be considered waste
(f) Sludge Thickener (gravity) ...................... 5 treatment. Likewise, discharges of wastewater from residences
(g) Dissolved Air Flotation Unit having a design flow of 1,000 gpd or less, shall not be subject to
(not applicable to a unit rates as (3) 0 ......... B rating -
(h) Sludge Gas Utilization (indudimg gas storage) .... 2
(i) Sludge Holding Tank.- , Aerated ................ S ADD1TtONAL OMMENTS-
Non-aerated ............ 2 -
�) Sludge Incinerator - (not including activated
carbon regeneration) .... - 10
(k) Vacuum Filler, Centrifuge or Filler Press or other
similar dewalering devices . - . - .. - - • • - - S0
(8) SLUDGE DISPOSAL (including incinerated ash)
(a) Lagoons ......................................... 2
n
(b) Land Application (surface and subsurface) G )-� t/0
(see deGnWon 22a)
-where the facility holds the land app. permit ... 10 r f
-by contracting to a land application operator who S� de , D y10r L
holds the land application permit ................ 2
-land application of sludge by a contractor who does
not hold the permit for the wastewater treatment
facility where the sludge is generated ......... 10
(c) Landfilled (burial) ............................. 5
(9) NFECT'ION
(a) Chlorination ........................ ..... 5
(b) Dechlorinalion ........................ 5
(e) Ozone ------------------------------
(d) Radialion .......................... 5