NCG170054_COMPLETE FILE - HISTORICAL_20131008

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STORMWATER DIVISION CODING SHEET
NCG PERMITS
PERMIT NO.
DOC TYPE,
HISTORICAL FILE
❑ MONITORING REPORTS
DOC DATE
❑ ❑ 3 ) u
YYYYM M D D

Romanski, Autumn
From:
Whaley, Mary
Sent:
Tuesday, October 08, 2013 11:41 AM
To:
[e-mail]
Cc:
Shackelford, Dennis, Romanski, Autumn; Jesneck, Charlotte; Ware, Bonnie
Subject:
FW: Hanes - Mt. Hope Finishing company latex waste ponds
Mr. Lichvar- I had forwarded Autumn Romanski's a mail to the Inactive hazardous wastes group and below is their
response- I don't know if this will be of any help.
Mary Whaley
Environmental Senior Specialist
NC Department of Environment and Natural Resources, Division of Waste Management, Solid Waste Section
Division Address: 1646 Mail Service Center, Raleigh, NC 27699-1646
Office Address: P.O. Box 59, Oxford, NC 27565
[e-mail]
919-693-5023
http://porta1.ncdenr.org/web/wm/­sw
E-mail correspondence to and from this address may be subject to the North Carolina Public Records Law and may be
disclosed to third parties.
Go Green! Print this email only when necessary. Thank you for helping NCDENR be environmentally responsible.
From: Jesneck, Charlotte
Sent: Tuesday, October 08, 2013 11:28 AM
To: Whaley, Mary; Ware, Bonnie
Cc: Caulk, Kim
Subject: RE: Hanes - Mt. Hope Finishing company latex waste ponds
We have a site called "Mount Hope Facility at 2000 Donald Ross Rd. This is an incident we inherited from DWR. The
incident number is different from the ones listed below. We have 7211— solvents in a septic tank. This site is
undergoing a voluntary remedial action under our REC Program. All of our records are publicly accessible on line. If this
is the site you are interested in, you can either view the records on line or call Kim Caulk if you have questions. He is our
REC Program Manager. Since these are independent actions, he will not know a lot of the site details. He can be
reached at 707-8350.
From: Romanski, Autumn
Sent: Tuesday, October 08, 2013 10:11 AM
To: Larry Lichvar
Cc: 'Theresa Block'; Lynn Crouse; 'Brian Anauo'; Whaley, Mary
Subject: RE: Hanes - Mt. Hope Finishing company latex waste ponds
Mr. Lichvar,

I have completed a search for the record you requested and unfortunately, it appears that the records may have been
destroyed under the Raleigh Regional Office retention policy at that time. (See comments from Mark below)
Mr. Mark Holland, Archive Analyst was able to identify records dated 1989-1999 and 1998-2000 under Department
listings, but the time frame is later than 1984, no Mount Hope Finishing Plant records were found, and no waste pond
closure documents were found.
The search was conducted under Water Quality Records. There is a possibility that the Division of Solid Waste may have
records, but again records dating back to 1984 may be difficult to obtain with the retention policy of that time. The
Division of Solid Waste can be reached at 336-771-5092 or Mary Whaley (Granville County) can be reached at 919-693-
5023. The solid Waste web site link is:
http://Portal.ncdenr.org/web/wm/sw
*Please contact myself, and /or Mary Whaley if we can be of assistance in providing a site visit to determine the "current
status of the waste ponds, or solid waste disposal on the site".
Thank you for your patience for us to research our records.
Sincerely,
Autumn Romanski
mi
Autw Rom m —
wloe '0... q 0191191w253
RA.^1427a ru(919)36,71$9
haw.i 0.ar.mt�9KDENR Vie
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Email correspondence to and from this address is
subject to the North Carolina Public Records Law
and may be disclosed to third parties unless the
content is exempt by statute or other regulation.
FROM: Mark Holland
I only found two that we have listings for:
25679 - Waste Disposal Permit Reviews File (1989-1999)
25681 - Groundwater Pollution Incidents File (1998-2000)
However, I have included a link to the retention schedule for the Raleigh Regional Office (which we are in the process of
updating). Several record series therein are listed as "destroy in office'. It may be that the particular file you are
searching for fell under that umbrella. I have provided the link below, for your reference:
http://statesched u les. ncdcr.gov/Schedules/D E N R/Assistant%20Secreta ry%20for%20Ad m i n i stratio n/Ra le igh%20Regio na l
%200ffice/DEN RassistsectyadminREG IONALOFFICES. pdf

I hope you were able to find someone at the Regional Office who was able to assist you. I will keep in contact with you.
Thanks,
Mark
Mark Holland
State Agency Records Management Analyst
State and University Records Unit
Department of Cultural Resources
ow
81 I.8 t
Division of Archives and Records
Government Records
a n 0
215 N. Blount Street
r'`
4615 Mail Service Center
1h, YOkl'
Raleigh, NC 27699-4615
Ph: [phone] 1 Fx: [phone]
www.records.ncdcr.gov
Opinions in this message may not represent the policies of this agency.
E-mail correspondence to and from this address may be subject to the North Carolina
Public Records Law "NCGS.Ch.132" and may be disclosed to third parties by an
authorized state official.
From: Larry Lichvar[mailto:larrv.Iichvar(dhanescomoanies.com]
Sent: Monday, September 23, 2013 3:29 PM
To: Romanski, Autumn
Cc: Theresa Block'; Lynn Crouse; 'Brian Anauo'
Subject: Hanes - Mt. Hope Finishing company latex waste ponds
Mrs. Romanski,
Thanks you for your return phone call and your assistance in the matter of the former latex waste ponds located at our
site in Butner, NC and used by the site's former owners ,Mt. Hope Finishing Company, prior to 1984. 1 we discussed, my
goal is to find documentation of the closure of these ponds in the NC DENR files. I have attached a copy of the following:
• Notice of Violation letter dated October 19, 1983 from Robert F. Helms.
• A letter regarding waste -pond cleanup (proposal review) dated January 19, 1984 from Lars Godwin, Water
Quality Supervisor, Raleigh Regional Office.
• A letter outlining the waste pond cleanup dated February 7, 1984 from Gerald Lundy, Mt. Hope Finishing
Company, Production Superintendent.
• A letter regarding the disposal of latex sludge dated January 17, 1984 from J. Gordon Layton, Environmental
Engineer, NC DENR Solid and Hazardous waste management branch
• Partial site map with the location of the former waste ponds located on a parcel to the south of the facility and
the southern railroad line adjacent to the site.
As we discussed, I hope that this documentation will give a better picture as to where to find the closure documentation
that I am seeking.
Best regards,
Larry Lichvar
Environmental & Safety Manager
Hanes Dye & Finishing Company
Ph: [phone]

flIAN ES
0YE ANO FINISHING CO
oC &'
� COMPANY
600 NORTHWEST OLVO. • P.O.00X 202 • WINSTON-SALEM, N.C. 27102-0202 • PHONE "fi-725-091
OD�1
1 November 2007
Mr. Myrl A. Nisely
Environmental Chemist
NC DENR DWQ
Surface Water Protection
1628 Mail Service Center
Raleigh, NC 27699-1628
Dear Mr. Nisely:
In response to your follow up letter from the Hanes Dye & Finishing Mount Hope
plant stormwater compliance evaluation inspection of October 3, 2007, I would
like to submit the following information for your files.
The city water flow discovered coming into the stormwater line was indeed
connected to the fire system. It was due to a cracked water pipe and has been
repaired. This years stormwater awareness training is scheduled for this month
(November)and will include all employees. The redirecting of the air
compressor condensate and bypassing of the collection pit does appear to be
feasible and will be implemented as soon as time permits and resources are
available. The cleaning up of the black crumbly material from the abandoned
concrete, clearing of the stormwater inlet and eliminating or moving of the I
beams and carts is in progress. Housekeeping around all dumpsters has improved
as noted in the October monthly stormwater inspection sheet. Lastly, Roger
Baucom has been informed as to the whereabouts and content of the stormwater
program to assist with future inspections.
Please feel free to contact me at [phone] x 3734 if you have any
questions or comments about this inspection response.
Sincerely,
Larry R. Lichvar
Environmental Manager

Q; \o�OF WA7F9QG
7 �
O Y
Mr. Roger Baucom
Hanes Dye and Finishing
Mt. Hope Finishing Plant
405 W. B Street
Butner, NC 27509
Copy to:
Mr. Larry Lichvar
Environmental Manager
Hanes Dye and Finishing
600 Northwest Blvd.
P.O. Box 202
Winston-Salem, NC 27102
Dear Mr. Baucom and Mr. Lichvar:
October 5,
Michael P. Easley, Governor
William G. Ross, Jr., Secretary
North Carolina Department of Environment and Natural Resources
Coleco H. Sullins, Director
Division of Water Quality
1111,00001
DLL •
Subject: Stormwater Compliance Evaluation Inspection
Mt. Hope Finishing Plant
Permit No. NCG170054
Butner, NC
Granville County
It was a pleasure meeting you both and having the assistance of Mr. Lichvar during the inspection
on Wednesday, October 03, 2007.
The facility has a well -documented stormwater program (see attached checklist) that is being
implemented. Our records show this to be the first ever stormwater inspection at this site.
There were a few minor housekeeping improvements identified as we toured the site. You agreed
to shovel up several deposits of black crumbly material from the abandoned concrete near the
entrance road, clear an inlet that is partially covered by dirt and dead vegetation, move metal I -
beams and carts into a building instead of leaving them exposed to rain and tighten up the
housekeeping around the closed -top dumpster.
Also discussed was the possibility of piping air compressor condensate directly to the pump station
that discharges to the POTW, instead of passing through a large open pit first. The pit no longer
serves its original purpose when dyeing was done at the plant, and now tends to accumulate debris,
algae and rainwater. The relatively clean condensate is probably becoming contaminated in its pass
through the pit. Redirecting the flow would allow the pit to be filled and abandoned. Please
examine the feasibility of this change with plant management and with the POTW.
An interesting surprise during the inspection was the discovery of a city water flow (smelled of
chlorine) that I estimate at 5 gpm coming into an underground stormwater line. Our detective work
led us to believe it was from a line feeding fire hydrants. City Utility personnel were to be
contacted that afternoon. A Hanes employee stated that he had seen and heard the flowing water
the week before. This incident points out the importance of stormwater awareness training of all
employees so that an observation of something unusual like this is immediately reported to plant
management.
North Carolina Division of Water Quality Raleigh Regional Office
Internet: www.ncwateraualitvorn 1628 Mail Service Center
o'Ir
N�o7r[hCarolina
y at!l171111/
Surface Water Protection Phone [phone] Customer Service
Raleigh, NC 27699-1628 FAX [phone]
An Equal OpportunitylAffinative Action Employer — 50% Recycled110% Post Consumer Paper

Hanes SW CEI, October 3, 2007 Page 2 of 2
Finally, the local environmental contact should be knowledgeable about the stonmwater program,
have access to the Stonnwater Pollution Prevention Plan (SP3) manual and be able to assist with
future inspections.
Please respond in writing to this letter within 30 days of receipt. Your response should address the
feasibility of redirecting compressor condensate and closing the open pit, and the repair/elimination
of the otable water discharge to the stormwater system.
Than yod for your attention to these matters. If you have any questions or comments about the
inspection; Olease contact me at 919-791-4255.
Sincerely,
� a r
Myrl A. Nisely
Environmental Chemist
cc: RRO/SWP file
Central Files

Permit: NCG170054
SOC:
County: Granville
Region: Raleigh
Compliance Inspection Report
Effective: 08/01/04 Expiration: 07/31/09 Owner: Hanes Dye & Finishing Company
Effective: Expiration: Facility: Mount Hope Finishing Plant
405 W B St
Contact Person: Roger BBaaUuvvcWWom
Directions to Facility: y
System Classifications:
Primary ORC:
Secondary ORC(s):
On -Site Representative(s):
Related Permits:
Title:
Inspection Date: 1010312007 Entry Time: 09:05AM
Primary Inspector: Myrl Nisely
Secondary Inspector(s):
Butner NC 27509
Phone: [phone]
Certification:
Exit Time: 11:30 AM
Phone:
Phone:[phone]
Reason for Inspection: Routine Inspection Type: Compliance Evaluation
Permit Inspection Type: Textile Mill Products Stormwater Discharge COC
Facility Status: ■ Compliant ❑ Not Compliant
Question Areas:
E Storm Water
(See attachment summary)
Page: 1

Permit: NCG170054 Owner -Facility: Hanes Dye B Finishing Company
Inspection Date: 10/03/2007 Inspection Type: Compliance Evaluation Reason for Visit: Routine
Stormwater Pollution Prevention Plan
Yes
No
NA NE
Does the site have a Stormwater Pollution Prevention Plan?
■
❑
❑
❑
# Does the Plan include a General Location (USGS) map?
■
❑
❑
❑
# Does the Plan include a "Narrative Description of Practices'?
■
❑
❑
❑
# Does the Plan include a detailed site map including outfall locations and drainage areas?
■
❑
❑
❑
# Does the Plan include a list of significant spills occurring during the past 3 years?
■
❑
Cl
❑
# Has the facility evaluated feasible alternatives to current practices?
■
❑
❑
❑
# Does the facility provide all necessary secondary containment?
■
❑
❑
❑
# Does the Plan include a BMP summary?
■
❑
❑
❑
# Does the Plan include a Spill Prevention and Response Plan (SPRP)?
■
❑
❑
❑
# Does the Plan include a Preventative Maintenance and Good Housekeeping Plan?
■
❑
❑
❑
# Does the facility provide and document Employee Training?
■
❑
Cl
❑
# Does the Plan include a list of Responsible Party(s)?
■
❑
❑
❑
# Is the Plan reviewed and updated annually?
■
❑
❑
❑
# Does the Plan include a Stormwater Facility Inspection Program?
■
❑
❑
❑
Has the Stormwater Pollution Prevention Plan been implemented?
■
❑
❑
❑
Comment: There were a few housekeeping suggestions discussed. See cover letter
Qualitative Monitoring
Yes
No
NA
NE
Has the facility conducted its Qualitative Monitoring semi-annually?
■
❑
❑
❑
Comment: Monitoring is actually carried out monthly.
Analytical Monitoring
Yes
No
NA
NE
Has the facility conducted its Analytical monitoring?
❑
❑
■
❑
# Has the facility conducted its Analytical monitoring from Vehicle Maintenance areas?
❑
❑
■
❑
Comment:
Permit and Outfalls
Yes No
NA
NE
# Is a copy of the Permit and the Certificate of Coverage available at the site?
■
❑
❑
❑
# Were all outfalls observed during the inspection?
■
❑
❑ ❑
# If the facility has representative outfall status, is it properly documented by the Division?
❑
❑
■ ❑
# Has the facility evaluated all illicit (non stormwater) discharges?
■
❑
❑ ❑
Page: 3
Piz hT

Permit: NCG170054 Owner - Facility: Hanes Dye & Finishing Company
Inspection Date: 10/03/2007 Inspection Type: Compliance Evaluation Reason for Visit: Routine
Comment: Looking at the system revealed a flow of chlorinated city water into a
portion of the stormwater system, surmised to be a leak from a pipe feeding the fire
hydrants. City Utilities were contacted.
Page:4

AN ES
DYE AND FINISHING CO.
MOUNT HOPE PLANT
Telephone: 919 / 575-6501 405 West B Street • P.O. Box 209 • Butner, NC 27509 Fax: 919 / 575-6552
August 20, 2003
NC Department of Environment and Natural Resources
Water Quality Section, RRO
1628 Mail Service Center
Raleigh, NC 27699-1628 / Q-5V
Attention: Joe Albiston, Environmental Specialist
Subject: August 14, 2003 Wastewater Spill Volume Revision
Dear Mr. Albiston,
Two of the letters submitted to you on August 15 & 18, 2003 were incorrect in stating the volume of wastewater
that spilled into the storm water conveyance system at the Mount Hope Facility. The volume was originally
thought to be approximately 20,000 gallons. This could only be true if both of the wastewater pumps were
pumping wastewater to the surface consecutively. This scenario is not possible due to the fact that the pumps
had kicked the breaker that provides power to them and the alarm. When the pumps are operational, wastewater
cannot fill the pump station or containment area. Failure of the power supply to the wastewater pumps and
alarm system, due to being wired to the same circuit breaker, was the source of the wastewater overflow and
spill. At the time of the report, I had to rely on assumptions and approximations that were made by the
maintenance department personnel.
The initial estimate of 20,000 gallons was based on the wastewater pump specifications, but the pumps failed
and the spill occurred due a natural gravity feed from the facility processes to the wastewater pump station. An
average flow for the facility is 300,000 gallons per day. With the wet well filled to capacity, an unassisted flow
from the wastewater pump station for a period of five minutes would be approximately 1,050 gallons. Given
the hole in the side of the building from which the wastewater was also escaping, an additional 950 gallons was
added to the approximation.
If there are any comments, concerns, questions, and/or suggestions, please don't hesitate to contact me.
Respectfully Submitted,
Robert M. Nations, AEP
Environmental Specialist
Hanes Dye & Finishing Company
P.O. Box 202
Winston-Salem, NC 27102-0202
[phone]
Aywecr,v'Vu/la COMPANY

AN ES
DYE AND FI NISH ING CO.
MOUNT HOPE PLANT
Telephone: 919 / 575-6501 405 West B Street • P.O. Box 209 • Butner, NC 27509 Fax: 919 / 575-6552
CC: Tom McGee, Butner Town Manager
Fred Dancy, Director of Butner Public Utilities
Chief Wayne Hobgood, Butner Public Safety
Doug Logan, Director of Granville County Emergency Management
Richard Horton, Vice President & General Manager, Mount Hope Plant
Randy Snyder, President, Hanes Dye & Finishing Company
Mark Linville, Corporate Finance Officer, Hanes Companies
Dennis Tart, Environmental Manager hanes Dye & Finishing Company
Roger Baucom, Plant Engineer Mount Hope Plant
Chris Hawks, Mount Hope Plant Superintendent
A dCN6e"V&COMPANY

AN ES
DYE AND FINISHING CO.
MOUNT HOPE PLANT
Telephone: 919 / 575-6501 405 West B Street • P.O. Box 209 • Butner, NC 27509
August 18, 2003
Butner Public Utilities'
205 — C West E Street O o
Butner, NC 27509 r `L
Q° C
Attention: Fred Dancy Q
Q-
0
Dear Mr. Dancy,
Fax: 919 / 575-6552
On August 14, 2003, you discovered a white milky substance in the wet well of the new pump station adjacent
to our property. After investigating the origination of the substance through manhole observation, it was
concluded that the substance was coming from the Hanes Dye and Finishing Mount Hope Plant. Determining
how the substance was getting into the sewer system presented Hanes with an accurate depiction of the way that
the latex sludge holding tank is actually plumbed.
The original design and operation of the latex waste recovery system was as follows:
➢ All latex left the inside of the manufacturing plant via floor drains and entered an open grate underground
holding tank
➢ From the tank the waste was pumped to the lined latex holding pond
➢ Latex is pumped from the lined latex holding pond up into the settling tanks where a polymer and an
activator are used to separate the solids
➢ The supernatant is decanted to the wastewater aeration lagoon and the solids discharged to the drying beds
➢ Dried solids are removed from the drying bed and placed in a roll -off container for land field disposal.
Over time latex solids begin to build up in the latex holding tank and must be pumped out with a pump truck.
The latex pump was constantly losing its prime as the levels of solids increased. When this would occur the
majority of the latex wash down water and solids were collected in tote tanks. The tote tank contents and the
latex solids that were pumped from the holding tank were deposited in the latex holding pond. Using tote tanks
and pumping solids from the holding tank became a normal occurrence as the latex pump constantly
encountered problems.
The aforementioned latex holding tank was built with an overflow pipe that was believed to be flow to the
wastewater aeration lagoon in the event of a tank overflow. Based on your investigation, we are now painfully
aware that this is not the case and that the overflow entered the sewer system.
A'Vrefy(&/COMPANY

AN ES
DYE AND FINISH INGCO.
MOUNT HOPE PLANT
Telephone: 919 / 575-6501 405 West B Street • P.O. Box 209 • Butner, NC 27509 Fax: 919 / 575-6552
To prevent the improper release and discharge of latex wastes from occurring in the future, the flowing actions
are being taken:
➢ A new latex pump will be installed this week
➢ The overflow valve will be grouted in by Friday August 22, 2003
➢ Chemical bench testing, availability, and cost of a mobile filter belt press system are being expedited to:
o Lessen environmental liability associated with lined liquid containment lagoons
o Increase waste disposal efficiency and alleviate the pumping and containment problems
As more information is gathered and progress is made you will be promptly be informed for advise and
approval. If there are any comments, concerns, questions, and/or suggestions, please don't hesitate to contact
me.
Resppect-fully Submitted,
Robert M. Nations, AEP
Environmental Specialist
Hanes Dye & Finishing Company
P.O. Box 202
Winston-Salem, NC 27102-0202
[phone]
[phone] FAX
CC: Tom McGee, Butner Town Manager
Joe Albiston, Environmental Specialist, NC DENR, Water Section, RRO
Chief Wayne Hobgood, Butner Public Safety
Doug Logan, Director of Granville County Emergency Management
Richard Horton, Vice President & General Manager, Mount Hope Plant
Randy Snyder, President, Hanes Dye & Finishing Company
Mark Linville, Corporate Finance Officer, Hanes Companies
Dennis Tart, Environmental Manager hanes Dye & Finishing Company
Roger Baucom, Plant Engineer Mount Hope Plant
Chris Hawks, Mount Hope Plant Superintendent
A 1(paee,&u& COMPANY

VANES
DYC AND FINISHING CO.
MOUNT HOPE PLANT
Telephone: 919 / 575-6501 405 West B Street • P.O. Box 209 • Butner, NC 27509 Fax: 919 / 575-6552
August 20, 2003
NC Department of Environment and Natural Resources
Water Quality Section, RRO
1628 Mail Service Center
Raleigh, NC 27699-1628
Attention: Joe Albiston, Environmental Specialist
Subject: August 14, 2003 Wastewater Spill Volume Revision
Dear Mr. Albiston,
Two of the letters submitted to you on August 15 & 18, 2003 were incorrect in stating the volume of wastewater
that spilled into the storm water conveyance system at the Mount Hope Facility. The volume was originally
thought to be approximately 20,000 gallons. This could only be true if both of the wastewater pumps were
pumping wastewater to the surface consecutively. This scenario is not possible due to the fact that the pumps
had kicked the breaker that provides power to them and the alarm. When the pumps are operational, wastewater
cannot fill the pump station or containment area. Failure of the power supply to the wastewater pumps and
alarm system, due to being wired to the same circuit breaker, was the source of the wastewater overflow and
spill. At the time of the report, I had to rely on assumptions and approximations that were made by the
maintenance department personnel.
The initial estimate of 20,000 gallons was based on the wastewater pump specifications, but the pumps failed
and the spill occurred due a natural gravity feed from the facility processes to the wastewater pump station. An
average flow for the facility is 300,000 gallons per day. With the wet well filled to capacity, an unassisted flow
from the wastewater pump station for a period of five minutes would be approximately 1,050 gallons. Given
the hole in the side of the building from which the wastewater was also escaping, an additional 950 gallons was
added to the approximation.
If there are any comments, concerns, questions, and/or suggestions, please don't hesitate to contact me.
Respectfully Submitted,
Robert M. Nations, AEP
Environmental Specialist
Hanes Dye & Finishing Company
P.O. Box 202
Winston-Salem, NC 27102-0202
[phone]
A J e("iV4 COMPANY

AN ES
DYE AND FINISHING CO.
MOUNT HOPE PLANT
Telephone: 919 / 575-6501 405 West B Street • P.O. Box 209 • Butner, NC 27509 Fax: 919 / 575-6552
August 15, 2003
NC Department of Environment and Natural Resources///
Water Quality Section, RRO 0
1628 Mail Service Center
Raleigh, NC 27699-1628
Attention: Joe Albiston, Environmental Specialist
Q�
Dear Mr. Albiston,
On August 14, 2003 the Hanes Dye & Finishing Plant in Butner, NC experienced a wastewater spill from the
plant wastewater pump house that pumps wastewater to the 2.0 million gallon wastewater aeration lagoon. The
source of the spill was the failure of two wastewater pumps that overloaded the electrical circuit. This was a
result of a faulty electric eye that caused both pumps to activate at the same time overloading the circuit. The
electric was replaced. The pump house has containment with a high water alarm. Unfortunately the alarm was
also connected to the same circuit as the wastewater pumps, which had overloaded the circuit breaker and lost
power. By the close of business on Friday August 15, 2003, the high water alarm will be rewired to a separate
circuit. The two problems that created this situation were fixed temporarily to keep the system from failing
until drastic measures to reengineer the pump and alarm wiring can be completed. New inspections and
company SOPs will be developed to aid in finding a future potential issues before the become problems.
Fred Dancy, Director of Butner Public Utilities was at our facility investigating a problem with Butner's new
pump station located adjacent to the Mount Hope Plant wastewater discharge from our facility to the city. Mr.
Dancy observed the wastewater pump house containment area with a rising volume of wastewater. He alerted
our plant engineer, Roger Baucom, of the situation. During that time the wastewater containment overflowed
for a time of approximately 5 minute with an estimated wastewater loss of 20,000 gallons before power could
be restored to the pumps.
As a result of the spill, the wastewater entered the storm water conveyance system and flowed southeast along
side of the latex holding pond. Approximately 400 feet from the spill origination point is a sliding gate that
impedes the flow of water past the culvert pipe, which it is attached.
Maintenance used pumps to pump the spilled wastewater from the storm water conveyance system. The pumps
were not successful in pumping a large enough volume to keep the wastewater from flowing further into the
storm water conveyance system. Environmental Management Solutions were called to dispatch a vacuum
pump truck with extra hose. The pumping crew arrived at 9:00 PM and began pumping the wastewater out of
the storm water conveyance system. Wastewater was pumped into their 3,200-gallon vacuum truck and
discharged into the facility's wastewater aeration lagoon. Pumping continued throughout the night.
The morning of August 15, 2003 high power pumps, hoses, and a mini excavator was ordered and due for
deliver around 12:00 noon.
A J(p Gw COMPANY

AN ES
DYE AND FINISH ING CO.
MOUNT HOPE PLANT
Telephone: 919 / 575-6501 405 West B Street • P.O. Box 209 • Butner, NC 27509 Fax: 919 / 575-6552
As more develops, I will update you. If you have any comments, concerns, questions, and/or suggestions,
please don't hesitate to contact me at the Mount Hope Facility at [phone] or my cell phone (336) 749-
2070.
This e-mail is being sent via our Mount Hope Quality Control Manager's e-mail account.
Respectfully Submitted,
Robert M. Nations, AEP
Environmental Specialist
Hanes Dye & Finishing Company
P.O. Box 202
Winston-Salem, NC 27102-0202
[phone]
A �P✓Vu/!G COMPANY

Tw-
State of North Carolina
Department of Environment
and Natural Resources
Division of Water Quality
James B. Hunt, Jr., Governor
Wayne McDevitt, Secretary
Kerr T. Stevens, Director
JOHN MILLIKEN
MT. HOPE FINISHING CO-JOHN MILLIKEN
P.O. BOX 147
BUTNER. NC 27509
Dear Permittee:
NCDENR
NORTH CAROLINA DEPARTMENT OF
ENVIRONMENT AND NATURAL RESOURCES
July 28, 1999
Subject: Reissue - NPDES Stormwater Permit
Mt. Hope Finishing Co -John Milliken
COC Number NCG 170054
Granville County
In response to your renewal application for continued coverage under general permit NCG170000, the Division of
Water Quality (DWQ) is forwarding herewith the reissued stormwater general permit. This permit is reissued
pursuant to the requirements of North Carolina General Statute 143-215.1 and the Memorandum of Agreement
between the state of North Carolina and the U.S. Environmental Protection Agency, dated December 6, 1983.
The following information is included with your permit package:
* A copy of general stormwater permit NCG 170000
* A Stormwater Pollution Prevention Plan (SPPP) Certification Form. Completion of this form is required to
certify that you have developed and implemented the SPPP as per the conditions of the permit. This form
must be completed and returned to the Division within 30 days of receipt of this letter.
DO NOT SEND the SPPP with the signed form.
* Five copies of the Analytical Monitoring form and five copies of the Qualitative Monitoring form
* A copy of a Technical Bulletin for the general permit which outlines changes in the permit, key requirements,
and addresses frequently asked questions
* A Certificate of Coverage
Your coverage under this general permit is not transferable except after notice to DWQ. The Division may require
modification or revocation and reissuance of the Certificate of Coverage. This permit does not affect the legal
requirements to obtain other permits which may be required by DENR or relieve the permittee from responsibility
for compliance with any other applicable federal, state, or local law, rule, standard, ordinance, order, judgment, or
decree.
If you have any questions regarding this permit package please contact Tony Evans of the Central Office Stormwater
and General Permits Unit at [phone], ext. 584
Sincerely,
f3�
for Kerr T. Stevens
cc: Central Files
Stormwater and General permits Unit Files
Raleigh Regional Office
1617 Mail Service Center, Raleigh, North Carolina 27699-1617 Telephone [phone] Fax [phone]
An Equal Opportunity Affirmative Action Employer 50% recycled/ 10% post -consumer paper

STATE OF NORTH CAROLINA
DEPARTMENT OF ENVIRONMENT AND NATURAL RESOURCES
DIVISION OF WATER QUALITY
GENERAL PERMIT NO. NCG170000
CERTIFICATE OF COVERAGE No. NCG170054
STORMWATER DISCHARGES
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,
MT. HOPE FINISHING CO-JOHN MILLIKEN
is hereby authorized to discharge stormwater from a facility located at
MT. HOPE FINISHING CO-JOIIN MILLIKEN
WEST B STREET
BUTNER
GRAN V ILLE COUNTY
to receiving waters designated as it UT of the Neuse River in the Neuse River Basin
in accordance with the effluent limitations, monitoring requirements, and other conditions set forth in Parts 1, 11, 111,
IV, V, ❑nd VI of General Permit No. NCG 170000 as attached.
This certificate of coverage shall become effective August I, 1999.
This Certificate of Coverage shall remain in effect for the duration of the General Permit.
Signed this day July 28, 1999.
for Kerr T. Stevens, Director
Division of Water Quality
By Authority of the Environmental Management Commission

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 Howardi Jr., P.E., Director
March 24, 1995
John Milliken
Mt. Hope Finishing Co.
P:O. Box 147
Butner, NC 27509
A4
IDEHNR
'Subject: General Permit No. NCG 170000
Mt. Hope Finishing Co.
COC NCG 170054
Granville County
Dear John Milliken:
In accordance with your application for discharge permit received on January 30, 1995, we are
forwarding herewith the subject certificate of coverage to discharge under the subject state - NPDES general
permit. This permit is issued pursuant to the requirements of North Carolina General Statute 143-215 .1 and
the Memorandum of Agreement between North Carolina and the US Environmental Protection agency dated
December 6, 1983.
If any parts, measurement frequencies or sampling requirements contained in this permit are
unacceptable to you, you have the right to request an individual permit by submitting an individual permit
application. Unless such demand is made, this certificate of coverage shall be final and binding.
Please take notice that this certificate of coverage is not transferable except after notice to the Division
of Environmental Management. The Divisionof Environmental Management may require modification or
revocation and reissuance of the certificate of coverage.
This permit does not affect the legal requirements to obtain other permits which may be required by the
Division of Environmental Management or permits required by the Division of Land Resources, Coastal
Area Management Act or any other Federal or Local governmental permit that may be required.
If you have any question concerning this permit, please contact MR. ANTONIO EVANS at telephone
number 919/733-5083.
cc: Raleigh Regional Office
'Sincerely, signed BY
Orivinal
t;c„ an ii. Sullins
A. Preston Howard, Jr. P.E.
P.O. Box 29535, Raleigh; North Carolina.27626-0535 .Telephone [phone] FAX [phone]
An EquatOpportunity Affirmative Action Employer 50% recycledt 10% postconsumerpaper

� �'f

STATE OF NORTH CAROLINA
'DEPARTMENT OF ENVIRONMENT, HEALTH, AND NATURAL RESOURCES
DIVISION•OF ENVIRONMENTAL MANAGEMENT
GENERAL PERMIT NO. NCG170000
CERTIFICATE' OF COVERAGE No. NCG170054
STORMWATER DISCHARGES
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,
Mt. Hope Finishing Co.
is hereby authorized to discharge stormwater from a facility located at
Mt. Hope Finishing Co.
West B Street
Butner, NC
Granville County
to receiving.waters designated as an unnamed tributary to the Neuse River in the Neuse River Basin
in accordance with the effluent limitations, monitoring requirements, and other conditions set forth in Parts I, 11, III
and IV of General Permit No. NCG 170000 as attached.
This certificate of coverage shall become effective March-24, 1995.
This Certificate of Coverage shall remain in effect for the duration of the General Permit.
Signed this day March 24, 1995.
Original Signed By
Coleen H. Sullins
A. Preston Howard, Jr., P.E., Director
Division of Environmental Management
By Authority of the Environmental Management Commission

MILE
2 �986
PROGRAMS -
ROAD CLASSIFICATION
Primary highway, Light -duty road, hard or
hard surface----_, improved surface_.._
Secondary highway,
hard surface ...... .._..... ..... Unimproved road ......... ...
______
0 Interstate Route C U. S. Route O State Route
LAKE MICHIE, N. C.
QUADRANGLE LOCATION NE/4 DURHAM NORTH 15' QUADRANGLE
N3607.5—W7845/7.5
1977
AMS 5256 III NE -SERIES V842
3
MODELING FILE
Made[i nj
C Z3l• • re

IN
ST�v
i North Carolina Department of Natural
�g Resources &Community Development
-„ - James B. Hunt, Jr., Governor James A. Summers, Secretary
DIVISION OF ENVIRONMENTAL MANAGEMENT
January 1.9, 1984
Mr. Jerry Lundy
Mt. Hope Finishing
P.O. Box 147
Butner, N.C. 27509
Dear Mr. Lundy:
Subject: Wastepond Cleanup
Mt. Hope Finishing
Granville County
The Raleigh Regional Office has reviewed your proposal for cleanup of the
wasteponds behind your facility in Butner. We have no objection to the methods
and facilities to be used. We suggest that you consider pH adjustment prior
to discharge to the pretreatment system. It is recommended that you proceed
at once and submit to our office a schedule for completing the cleanup. If
you desire a tax certificate then a non -discharge application along with two
sets of plans and specifications and a permit fee of $100.00 must be sub-
mitted.
If you have any questions concerning this matter please contact me or
Mr. R. H. Ferneyhough at the number below.
Sincerely,
Lars D. Godwin
Water Quality Supervisor
Raleigh Regional Office
LDG/lbb
cc: Dale Crisp
Raleigh Regional Office 3800 8arretl Drive, P, O. Boa 27687, Raleigh, N.C. 27611 7687 Telephone [phone]
An Equal Opportunity A(Ifrmafive Action Employer

STA
3 North Carolina Department of Natural
Resources &Community Development
James B I-ii u1l, .L , Governor Joseph W. (; rimsley, Secretary
^ October 19, 1983
CERTIFIED MAIL
RETURN RECEIPT REQUESTED
Mr. Felix Buba
Vice President
Mt. Hope Finishing Company
Butner, NC 275C9
Dear Mr. Buba:
DIVISION OF
ENVIRONMENTAL
MANAGEMENT
Rotxn F. Helms
ou.tol
Te4:Ph.n 919 733 7015
SUBJECT: Notice of Violation
Wastewater Treatment Facilities
Granville County
On October 10, 1983 Mr. Lars Godwin, Mr. R.H. Ferneyhough and Mr. William
Dail of our Raleigh Regional Office investigated a complaint concerning the
dumping of waste material behind the Mt. Hope Finishing Company in Butner,
North Carolina. Their investigation revealed that three holding ponds or
lagoons had been constructed and that solid and liquid wastes had been
dumped into these lagoons. p�R �+s
1 �
The construction and operatio of these lagoons is a direct violation of
N.C. General Statute 143-21.5.1(a) (2) and.(7). These violations are subject
to enforcement action in the form of civil penalties. To avoid these penalties,
Mt. Hope Finishing Company must submit to the Raleigh Regional Office plans for
cleaning the lagoons, returning the area to its original condition and disposal
of future waste products. These plans must be submitted within 90 days of
receipt of this letter. We suggest that you contact Mr. Joe Deakins with the
Division of Health Services at 563-1818 concerning the disposal of solid waste.
It was observed during the investigation that the stream running between
the lagoons was discolored due to some kind of discharge. It is recommended
that your plant piping systems be checked for Leaks or discharges into the
stream. In addition the existing lagoons should be bermed to prevent the
discharge of the contents. If you have further questions please contact
Lars Godwin at 919/733/2314.
Sincerely,
o;e X F. He ms
cc: Joe Deakins Director
Bobby Green
Larry Thomas
PO L L UTIOA' PR 111 EN T/0,V PA YS
An Equal Opportunity Affirmative Acllop Employ[,

MOUNT HOPE FINISHING COMPANY
BUTNER, NORTH CAROLINA 27509
Telephone [phone]
February 7, 1984
Mr. Lars Godwin
Water Quality Supervisor
Department of Natural Resources
Raleigh, North Carolina 27609
Subject: Waste pond clean-up schedule
Mount Hope Finishing Company
Granville County
Dear Mr, Godwin:
NEW YORK SALES AGENT
111 WEST 40TH STREET
NEW YORK, N.Y. 10018
The following is an outline including specific dates of completion
for the various steps involved in the clean up of: our waste pond site
at Mount Hope Finishing Company, I sincerely hope that this schedule is
in agreement with the standards of your people and that a satisfactory
completion time, with regards to all parties involved, can be achieved.
Should there be any questions regarding this schedule, please contact
me at Mt. Hope [phone] ext. 240.
-..__ -...-. ......... .. ........Sincerely., ...__.,.-
MOUNT HOPE FINISHING COMPANY
Gerald V. Lundy
Production Superintendent
GVL/mc
cc: Gordon Layton, NRCD
Sohn K. Milliken
George Staples
Mary M. Peed
Richard Miller
ROBERT D. MILLIKEN, Chairman
JOHN K. MILLIKEN, President
GEORGE A. STAPLES. Exec. Vice President
FELIX E. SUBA, Vice President
MARY M. PEED, Secretary & Treasurer

WASTE POND CLEAN UP SCHEDULE
MOUNT HOPE FINISHING COMPANY
RUINER, NORTH CAROLINA
FEB.. 7, 1984
L. Surveying and submission of plans by Olsen Engineering including
non -discharge application and permit fees to be completed by
3/1/84.
II. Review by water quality board to be completed by 4/1/84.
III. Construction of drying beds, modification and erection of treatment
tanks and all plumbing to be completed by 6/l/84.
IV. All waste ponds to be pumped out and treated by 10/l/84.
V. Waste pond site to be graded, seeded and closed off, to the public
by 11/1/84.

Ronald H. Levine, M.D., M.P.H.
STATE HEALTH DIRECTOR
DIVISION OF HEALTH SERVICES
P.O. Box 2091
Raleigh, N.C. 27602-2091
January 1.7, 1,984
Gerald V. Lundy
Production Superintendent
Mount Hope Finishing Company
Butner, NC 27509
Re: Disposal of Latex Sludge (1000 Cubic Yards Per Year) at
Granville County Landfill (39-02)
Dear Mr. Lundy:
The Division of Health Services has received a request for characterization of
the subject waste. Based upon the submitted information, the waste appears to
be non -hazardous. The Division of Health Services has no objection to the
sanitary landfill disposal of this waste if in accordance with the conditions
below:
1. The waste is non -liquid and can he confined, compacted, and covered
in accordance with the "Solid Waste Management Rules".
2. The owner/operator of the landfill approves the disposal.
3. The waste remains non -hazardous as determined by the current North
Carolina Hazardous Waste Rules regulations.
4. Additional analysis may be requested in the future.
Failure to meet these conditions may result in revocation of this approval and
an administrative penalty. This approval is subject to change if new
regulations were to prohibit this practice. If the process which generates
the waste changes or if the composition of the waste changes significantly,
this approval is voided, and re-evaluation of the waste will be required prior
to disposal.
If you have any questions concerning this matter, please contact our office at
[phone].
Respectfully, x/
J. Gordon Layton, Environmental Engineer
Solid b Hazardous Waste Management Branch
Environmental Health Section
JGL:dws
cc: Joe Deakins
Granville County Landfill
James 6 Hum, L Sarah T. Morrow, M.D, M Phi.
STATE OF NORTH CAROLINA GOVERNOR DEPARTMENT OF HUMAN RESOURCES SECRETARY

AN ES
DYE AND FINISH I NO CO.
MOUNT HOPE PLANT
Telephone: 919 / 575-6501 405 West B Street • P.O. Box 209 • Butner, NC 27509 Fax: 919 / 575-6552
August 18, 2003
Butner Public Utilities
205 — C West E Street
Butner, NC 27509
Attention: Fred Dancy
Dear Mr. Dancy,
On August 14, 2003, you discovered a white milky substance in the wet well of the new pump station adjacent
to our property. After investigating the origination of the substance through manhole observation, it was
concluded that the substance was coming from the Hanes Dye and Finishing Mount Hope Plant. Determining
how the substance was getting into the sewer system presented Hanes with an accurate depiction of the way that
the latex sludge holding tank is actually plumbed.
The original design and operation of the latex waste recovery system was as follows:
➢ All latex left the inside of the manufacturing plant via floor drains and entered an open grate underground
holding tank
➢ From the tank the waste was pumped to the lined latex holding pond
➢ Latex is pumped from the lined latex holding pond up into the settling tanks where a polymer and an
activator are used to separate the solids
➢ The supernatant is decanted to the wastewater aeration lagoon and the solids discharged to the drying beds
➢ Dried solids are removed from the drying bed and placed in a roll -off container for land field disposal.
Over time latex solids begin to build up in the latex holding tank and must be pumped out with a pump truck.
The latex pump was constantly losing its prime as the levels of solids increased. When this would occur the
majority of the latex wash down water and solids were collected in tote tanks. The tote tank contents and the
latex solids that were pumped from the holding tank were deposited in the latex holding pond. Using tote tanks
and pumping solids from the holding tank became a normal occurrence as the latex pump constantly
encountered problems.
The aforementioned latex holding tank was built with an overflow pipe that was believed to be flow to the
wastewater aeration lagoon in the event of a tank overflow. Based on your investigation, we are now painfully
aware that this is not the case and that the overflow entered the sewer system.
A epAV COMPANY

VANES
DYC AND FINISHING CO.
MOUNT HOPE PLANT
Telephone: 919 / 575-6501 405 West B Street • P.O. Box 209 • Butner, NC 27509 Fax: 919 / 575-6552
To prevent the improper release and discharge of latex wastes from occurring in the future, the flowing actions
are being taken:
➢ A new latex pump will be installed this week
➢ The overflow valve will be grouted in by Friday August 22, 2003
➢ Chemical bench testing, availability, and cost of a mobile filter belt press system are being expedited to:
o Lessen environmental liability associated with lined liquid containment lagoons
o Increase waste disposal efficiency and alleviate the pumping and containment problems
As more information is gathered and progress is made you will be promptly be informed for advise and
approval. If there are any comments, concerns, questions, and/or suggestions, please don't hesitate to contact
me.
Respectfully Submitted,
Robert M. Nations, AEP
Environmental Specialist
Hanes Dye & Finishing Company
P.O. Box 202
Winston-Salem, NC 27102-0202
[phone]
[phone] FAX
CC: Tom McGee, Butner Town Manager
Joe Albiston, Environmental Specialist, NC DENR, Water Section, RRO
Chief Wayne Hobgood, Butner Public Safety
Doug Logan, Director of Granville County Emergency Management
Richard Horton, Vice President & General Manager, Mount Hope Plant
Randy Snyder, President, Hanes Dye & Finishing Company
Mark Linville, Corporate Finance Officer, Hanes Companies
Dennis Tart, Environmental Manager hanes Dye & Finishing Company
Roger Baucom, Plant Engineer Mount Hope Plant
Chris Hawks, Mount Hope Plant Superintendent
A,J/p ,�f G &y COMPANY

Re: Hanes Dye & Finishing - Mount Hope Plant Spill August 14, 2003
Subject: Re: Hanes Dye & Finishing - Mount Hope Plant Spill August 14, 2003
Date: Mon, 18 Aug 2003 17:07:02 -0400
From: "robert.nations" <[e-mail]>
Organization: Hanes Dye and Finishing Company
To: Joe Albiston <[e-mail]>,
Richard Horton<richard. [e-mail]>,
Roger Baucom <[e-mail]>,
dennis tart <[e-mail]>, Fred Dancy <[e-mail]>
Joe,
The points of concern are addressed as follows:
1) The volume of discharge was based on the length of time of the over flow, on the pump curves, and
volume of wastewater that could be contained in the containment area and flowed out of the hole in the
wall.
2) Free board feet has been increased to 14 inches over the week -end and will continue to decrease in
volume.
3) We are currently exhausting every effort to get a mobile filter press system cost, chemical bench
tested, and nail down availability.
I'll update you on new information as it is obtained and ask for your advise where possible. If there are
any comments, concerns, questions, and/or suggestions, please don't hesitate to contact me.
Joe Albiston wrote:
•..
We have received the attached document.
The points of concern are:
1) The amount of discharge; 20,000 gallons in 5 minutes is this correct? This
seems to be
too high a flow?
2) The freeboard in the pretreatment lagoon. Upon my visit, the freeboard appeared
to be -
4 inches.
3) Maintenance of the pretreatment lagoon, referring to height of solids in the
lagoon.
-Joe
Ed Ayers wrote:
This e-mail is being sent by Rob Nations from Ed Ayers', Mount Hope
Quality Control Manager, e-mail account. See the attached document for
summary of the wastewater spill August 14, 2003
I of 2 08/19/2003 8:03 AM

Re: Hanes Dye & Finishing - Mount Hope Plant Spill August 14, 2003
Name: Aug.14, 2003 wastewater
spill.doc
Aug.14, 2003 wastewater spill.doc Type: Winword File
(application/msword)
Encoding: base64
Download Status: Not downloaded with message
Joseph (Joe) W. Albiston
Environmental Specialist II
NC Dept. of Environment and Natural Resources
Raleigh Regional Office
Div. Water Quality
1628 MAIL SERVICE CENTER
RALEIGH, NC 27699-1628
Telephone: [phone], Extension 267
Facsimile: [phone]
2 of 2 08/19/2003 8:03 AM

AN ES
DYE AND FINISHING CO.
MOUNT HOPE PLANT
Telephone: 919 / 575-6501 405 West B Street • P.O. Box 209 • Butner, NC 27509 Fax: 919 / 575-6552
August 15, 2003
NC Department of Environment and Natural Resources
Water Quality Section, RRO
1628 Mail Service Center
Raleigh, NC 27699-1628
Attention: Joe Albiston, Environmental Specialist
Dear Mr. Albiston,
On August 14, 2003 the Hanes Dye & Finishing Plant in Butner, NC experienced a wastewater spill from the
plant wastewater pump house that pumps wastewater to the 2.0 million gallon wastewater aeration lagoon. The
source of the spill was the failure of two wastewater pumps that overloaded the electrical circuit. This was a
result of a faulty electric eye that caused both pumps to activate at the same time overloading the circuit. The
electric was replaced. The pump house has containment with a high water alarm. Unfortunately the alarm was
also connected to the same circuit as the wastewater pumps, which had overloaded the circuit breaker and lost
power. By the close of business on Friday August 15, 2003, the high water alarm will be rewired to a separate
circuit. The two problems that created this situation were fixed temporarily to keep the system from failing
until drastic measures to reengineer the pump and alarm wiring can be completed. New inspections and
company SOPS will be developed to aid in finding a future potential issues before the become problems.
Fred Dancy, Director of Butner Public Utilities was at our facility investigating a problem with Butner's new
pump station located adjacent to the Mount Hope Plant wastewater discharge from our facility to the city. Mr.
Dancy observed the wastewater pump house containment area with a rising volume of wastewater. He alerted
our plant engineer, Roger Baucom, of the situation. During that time the wastewater containment overflowed
for a time of approximately 5 minute with an estimated wastewater loss of 20,000 gallons before power could
be restored to the pumps.
As a result of the spill, the wastewater entered the storm water conveyance system and flowed southeast along
side of the latex holding pond. Approximately 400 feet from the spill origination point is a sliding gate that
impedes the flow of water past the culvert pipe, which it is attached.
Maintenance used pumps to pump the spilled wastewater from the storm water conveyance system. The pumps
were not successful in pumping a large enough volume to keep the wastewater from flowing further into the
storm water conveyance system. Environmental Management Solutions were called to dispatch a vacuum
pump truck with extra hose. The pumping crew arrived at 9:00 PM and began pumping the wastewater out of
the storm water conveyance system. Wastewater was pumped into their 3,200-gallon vacuum truck and
discharged into the facility's wastewater aeration lagoon. Pumping continued throughout the night.
The morning of August 15, 2003 high power pumps, hoses, and a mini excavator was ordered and due for
deliver around 12:00 noon.
A dC4U�"J? COMPANY

AN ES
DYE AND FINISHING CO.
MOUNT HOPE PLANT
Telephone: 919 / 575-6501 405 West B Street • P.O. Box 209 • Butner, NC 27509 Fax: 919 / 575-6552
As more develops, I will update you. If you have any comments, concems, questions, and/or suggestions,
please don't hesitate to contact me at the Mount Hope Facility at [phone] or my cell phone (336) 749-
2070.
This e-mail is being sent via our Mount Hope Quality Control Manager's e-mail account.
Respectfully Submitted,
Robert M. Nations, AEP
Environmental Specialist
Hanes Dye & Finishing Company
P.O. Box 202
Winston-Salem, NC 27102-0202
[phone]
A O4 "'COMPANY

NORTH CAROLINA DEPARTMENT OF
ENVIRONMENT AND NATURAL RESOURCES
RALEIGH REGIONAL OFFICE
January 3, 2001
CERTIFIED MAIL
RETURN RECEIPT REQUESTED
Mr. Dennis Tart
Hanes Dye and Finishing Co.
Mount Hope Plant
405 West B Street
PO Box 147
Butner, NC 27509
Subject: Notice of Violation
Notice of Recommendation for Enforcement
Unlawful Discharge of Chemicals
Hanes Dye and Finishing; Mount Hope Plani
Butner, NC
Granville County
Dear Mr. Tart:
This office received a call from Mr. Dennis Tart on December 12, 2000
concerning an accidental discharge of a latex product from a broken pipe that
occurred on or about December 8, 2000. Upon investigation by this office, it was
determined that an estimated 555 gallons of waste water containing approximately
5000 pounds of the latex product flowed into an unnamed tributary that flows to Falls
Lake in the Neuse River basin.
This discharge of chemicals is a violation of North Carolina General Statute
143-215.1a, which states in part that it is unlawful to discharge pollutants or
hazardous substances into or upon any waters or lands of the State. General
Statute 143-215.1a states that no person shall discharge to waters of the state
unless the person shall have applied for and received a permit from the Director and
shall have complied with the conditions prescribed in the permit.
This unlawful discharge of chemicals to lands and waters of the State is
subject to enforcement action by this Division. This office may recommend to the
Director of the Division that an enforcement action be prepared for this violation of
North Carolina law. If you have reasons why this office should not pursue an
enforcement action for this violation, please submit your comments in writing to this
office no later than January 16, 2001.
MAILING ADDRESS: 1828 MAIL SERVICE CENTER, RALEIGH, NORTH CAROLINA 27699-1628
LOCATION: 3800 BARRETT DRIVE, SUITE 101, RALEIGH, NC 27609
PHONE [phone] FAX[phone]
AN EQUAL OPPORTUNITY / AFFIRMATIVE ACTION EMPLOYER - SO% RECYCLED/10% POST -CONSUMER PAPER

0
0
Mr. Tart
January 3, 2001
Page 2
To minimize the potential for future failures of the PVC pipe to the holding ttie pond the pipe
should be modified to meet minimum standards as would be required for permitted facilities. This
specifies that above ground pipe must be of ferrous material. An alternative is that a minimum
cover of three feet shall be provided for all exterior transfer pipe unless ferrous material pipe is
utilized. It is recommended that ferrous material pipe or other pipe with proper bedding to develop
design supporting strength shall be provided where the pipe is subject to traffic bearing loads.
Additionally, the pond intended to serve as containment for the large fuel tanks requires
substantial improvements. There appears to be considerable damage to the embankment
potentially from some type of rodents and tree root impacts. You may wish to contact the Granville
County Fire Marshall for further guidance. The containment structure must meet all applicable .
regulations for above ground storage tanks. This structure must be evaluated by a professional' '
engiheer and verified as sound, or a report should be made to indicate the modifications necessary..
to make the structure sound including a plan and time table for how the modifications are to'lie
implemented.
If you have questions concerning this notification please contact John Hunt or Judy Garrett
at 919-571-4700.
Sincerely,
2�
Kenneth Schuster, P.E.
Regional Supervisor
cc: Fred Dancy, Town of Butner
Granville Co. Health Dept.
Granville Co. Fire Marshall
s:/ Mthope.nov

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I w � 0*2'"1

IAN ES
DYE AND FINISHING CO @ A 4 6 COMPANY
WO NORTHWEST OLYD. # P.D. SOX 202 # WINSTON-SALEM, N,C. 21102.0202 • PHONE lh-72S-491
ENVIRONDIENI'AL DEPARTMENT: PHONE # [phone]
FAX # [phone]
ROB NATIONS EXT 3034 ENVIRONA'IEN'TAL SPECIALIST
DENNIS TART EXT 3103 ENVIRONMENTAL ENGINEER
(PAGER: 336-770-0509)
FAX TRANSMITTAL COVER SHEET
DATE: AUGUST 14, 2003
TO: JOE ALBISTON
FRONI: ROB NATIONS / DENNIS TART
NUMBER OF PAGES (INCLUDING COVER SHEET) 13
COMMENTS ATTACHED ARE ALL OF THE RESPONSE FORM
THAT WE PREVIOUSLY FILED IN A PRIOR SPILL AND MAY SERVE
USEFUL FOR YOUR RECORDS. A REVISION LETTER WILL BE
SUBiV11TTED TO YOU BY THE CLOSE OF BUSINESS TOMORRONNI
THAT HAS THE REVISED FLOW AND RATIONALE THEREOF. ALSO
INCLUDED WILL BE THE PRESS RELEASE FOR YOUR APPROVAL.
THANK YOU
Z'd OEEE 13Cb3SU_1 dH WdBb:L E00Z GI 2nd
00 ci ("Ai)20,61-9nv: aims .is r,.ea

Sewage Spill Response Evaluation:
(page 1 of 2)
Permittee pp 1Jr , I7lT i Permit Number 1`11� M1941MlS County G F'VWKLS
Incident Ended: (Date/Time) S O / ObW Estimated Duration (Time) 5—'m1 fJ
First knowledge of incident: (Date/Time) W &O 11
Estimated volume of spill/bypass ZZ0flQ gallons. Show rational for volume,
roD PGrnP Acnt, -?Czk slBz�L rnAX Flo Pt MK = zma CT)9"-'5.
ffspill is ongoiinn►g, please notify Regional Office on a daily basis until spill can be stopped.
Reported to: 07Q. /$:ibxj (Dateltime)
Name of person
Weather conditions: C ��
Source of spill/bypass (check one): _Sanitary Sewer _Pump Station ✓ WWfP
Level of treatment (check one): ' None _Primary Treatment
_ Secondary Treatment _ Chlorination Only
Did spill/bypass reach surface waters? Yes ►� No (If Yes, please list the following)
Volume reaching surface waters? U OKA5bLQ#4 gallons I -
Name of surface water—xeAfiE =7Liz= elt1eaft.rr l
Did spill bypass result in a fish kill? _Yes -�/—* No
If Yes, what is the estimated number of fish killed?
Please provide the following Information:
1. Location of
.Car646:�> U35Z ih -P
6eF-fl -V yytr r�4 Apw E.
Sum. w�rZ�ZS ,
3. Did you have personnel available to perform initial assessment 24 hours/day (including weekends and
holidays)?
Yes y No
How long did it lake to make an initial assessment of the spill/overflow after first knowledge?
Hours _.!5�- Minutes
How long did it take to get a repair crew onsite?
Hours 06QT— Minutes
Please a)plain the time taken to make initial assessment:
C -d OCCC 13Cb3SU-1 dH WdBti:L cooa ST 2nd
200 'c S i (3n1) 40 ,61 - '0f1V: alel,L/31Y0 .A`J

Sewage Spill Response Evaluation:
(Page 2 of 2)
Permittee A'QFF--Ar. AcWF. Permit Number 7t 6E iQU\M l:ounty q9AA_VM4j6-
5. Action taken to contain spill, clean up waste, and/or remediate the site:
6. Were the equipment and parts needed to make repairs readily available?
Yes J,-� No If no, please explain why:
If the spill/overflow occurred at a pump station, or was the result of a pump station failure,
was the alarm system functional at the time of the spill? Yes No _� If the alarm
system did not function, please explain why:
8. Repairs made are: Permanent Temporary
Please describe what repairs were made. If the repairs are temporary, please indicate a date by
which permanent repairs will be completed, and notify the Regional Office within 7 days of the
9. What actions have been made to prevent this discharge from occurring again in the future?
10.
Other agenciesr4otifed: Cr QA4=aF' CAw02y �i fl , l +lT�
0XVW {I'ra�lCff iyF�ry -DoU&
Person reportingspill/bypass_: ,h Bfrbn5 Phone Number. *41et S-r34/
SignatureDater
For DWQ Use Only:
DWQ requested additional written report? _Yes No
If yes, what additional information is needed?
Requested by
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h0o � 7C SI (Erl.L)EO.61-'IMV: N2i

OPER,kTION & MAINTENANCE EVALUATION
Permittee N L /-4L ,6�ermit Number?b ?5- t�t�.r�►rt�County ,Gyiw14dE.
1. Is staff designated full-time for collection system operation and maintenance? Yes No
2. Do you have a list of 24-hour contacts? Yes No (If Yes, please attach)
3. Do you have an emergency equipment list? Yes No (if Yes, please attach)
4. Staff distributionitime allocation:
Number Total staff
employed hoursJweek
Collection System (incl. part-time) _
Pump Stations _
Ill Correction
5. Are map(s) of the collection system available? Yes I/ No
6. Total number of pump stations: _ (Please complete a Pump Station form for each station.)
Is a preventive maintenance program in effect? Yes
If yes, does it include:
a. Maintaining logs/records
(maintenance, inspection, etc)
b. Trouble log (equipment/system malfunctions)
c. Establishing schedules
d. 1/1 evaluation
e. Manhole inspection
f. Sewer cleaning program
g. Hydrogen sulfide monitoring and control
h. Lift station operation
I. Easement/right-of-way maintenance
j. "Walking" or visual observation of lines
k. Spare parts inventory
No (If Yes, please attach)
Yes No
Yes
No
✓ Yes
No
Yes
✓
No
Yes
No
Yes
✓
No
Yes
✓
No
Yes
✓
No
Yes
No
Yes
No
Yes
No
i3. Please describe what type of ongoing inspection program for the collection system exists.
1 2,4( oP i r=Y?_M 6-1ei9
- r
9. Please describe the schedule for line cleaning.
10, Is there a sewer use ordinance? ►rYes No. Is there a grease ordinance? ✓ Yes —No
If yes, please identify the responsible party for ensuring the ordinance(s) is followed.
F/QZ42—�DC" 1 642712ZdZ. 442' 1 ES (name/agency).
11, Please describe any sewer use ordinance enforcement practices that exist.
YS S VQ . L_"_0AJ tors — F., rwsW
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300 a si (snL)EO,ei- ",nv

PUMP STATION
(please complete one form for each pump station)
Name of Facility: Contact Person: ZMCQJA
Phone Number:
I
Location of Pur
Fume_
1: How often is pump station Inspected? once per day
(check all that apply) . once perweek
twice per day'
days Pef week
other(explairt)
2. What is the pump station capacity?_Zg�a_GPM
Dreg the pump station have a now meter, pump counters or other means to measure FloiR
_✓ - Yes —No •'
3. Does the pump station have a backup power source? _ Yes _A!!�: No
If yes, what We: Portable generator which can be moved to site J
Standby generator on site
Alternate power feed
If a portable generator Is used, how many other pump stations does the generator serve?
How often is the generator tested? (Moor.)
When was the generator last load tested? (MoJyr.)
Was the test successful? _ Yes _ No It No, what action was taken to address?
If no bacia.rp power exists, please explain why-,
a. Does the pump station have a working alarm system?__tL Yes No
On site alarm system High water audio alarm _ High water visual alarm
Other. (describe)
Telemetry Monitoring System: ✓ Wet well high level ✓ Wefwell low level
Dry well high level High/low pH
High/low current _jef AC power status
Please describe other alarm systems at the pump station.
5. Is there a spare pump available or an adequate spare pars inventory to replace or rebuild pump?
.L Yes _ NO If No, what actions are being undertaken to address'?
9'd OEEE 13Cd3SHH dH Wd80:L EOOZ GI rand
900 'd :11 SI (BfI,L)f0 .G I - "Yltl: 9N11/q_ltia .C�

PUMP STATION
(please complete one form for each pump station)
Name of Facility
C /f)i. DAL Contact PersoM �t BAut.pr�
Phone Number.
t
Location of Pump Station'
AI/f/"i�' rJ. _.%i 4�.1._«—�
1. How often Is pump slatlon Inspected? once per day twice per day
(check an that apply) once per week days per week
f other(explain) la,"4%1J k �
2. What Is the pump station capadty? 3�D GPM
Doe3.ihe pump station have a flow meter, pump counters or other means to measure flodv7
Yes _--No
3. Does the pump station have a backup power source? _ Yes —L,—No
If yes, what type: Portable generator which can be moved to site
Standby generator on site
Alternate power feed
If a portable generator Is used, how many other pump stations does the generator serve?
How often is the generator tested? (Molyr.)
When was the generator last load tested? (MoJyr.)
Was the test successful? _ Yes _ No It No, what action was taken to address?
r exists, please _explain why..:
4. Does the pump station have a working alarm system? 'Yes No
On site alarm system _High water audio alarm _✓High water visual alarm
Other(describe)
Telemetry Monitoring System: Wet well high level Werwell low level
Dry well high level High/low pH
Klgwow current AC power status
Please describe other alarm systems at the pump station.
S. Is there a spare pump available or an adequate spare parts Inventory to replace or rebuild pump?
Yes _ No It No, what actions are being undertaken to address?
L'd OEEE 13CNISUI dH WdGb:L C00a GS 9nd
Loo d tt, =aI (2n.L)20 31- onv� xa

PUMP STATION
(please complete one form. for each pump fstation)
Name of Facility: 112r,dffF Contact PerniJ. SZoGF.-� Qjy\
Phone Number.
l
LocaIli o�,o'Pump Station:
d/u M P ' /443 Z2c
1. How often Is pump station Inspected? once per day t� per day .
'.' (check all that apply) once per week days Per week
other(explain)
2. What Is the pump station capacity7—L±�LGPM
Does the pump station have a flow meter, pump counters or other means to measure flova
Yes If No
3. Does the pump station have a backup power source? _ Yes ✓No
If yes, what type: Portable generator which can be moved to site
Standby generator on site
Alternate power teed
If a portable generator is used, how many other pump stations does the generator serve?
How often is the generator tested? (MoJyr.)
When was the generator last bad tested? (Mojyr.)
Was the test successful? _ Yes _ No N No, what action was taken to address?
If no backup power exists, please explain why.. -
4. Does the pump station have a working alarm system? t:-f Yes No
On site alarm system: ✓High water audio alarm High water visual alarm
Other. (describe)
Telemetry Monitoring System: Wet well high level Werwell low level
Dry well high level High/low pH
High/lowcurrent AC power status
Please describe other alarm systems at the pump station.
S. Is there a spare pump available or an adequate spare parts Inventory to replace or rebuild pump?
✓Yes —No It No, what actions are being undertaken to address?
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9 0 U 'd 1,11'87 (811 IL120.61-'[HIV: 8NI'I,/3,LVa X�i

SPILL RESPONSE PLAN EVALUATION
Permittee dj2F- 41- % bX- Permit Number_c O Y& CountyGm"da.
1. Do you have a current 24-hour contact list that includes phone numbers of key personnel and/or
contractor;? ­1/ Yes No (if Yes, please attach)
2. Do you have an equipment list that includes available functional equipment and where the
equipment is located? __Yes No (If Yes, please attach)
3. Do you have the staff resources to make an on -site assessment of a spill within two hours of
notification of the spill? _Yes No (if No, please explain below)
4. Please list your standard spill response procedures:
9
5. Is your spill response plan readily available to all essential personnel? __Yes No
It No, please explain why:
6. Are all essential personnel familiar with the spill response plan and do they cleaq understand its
conten s?
_Yes No
If No, please explain wny:
6•d OEEE 13CNISH-i dH WdOS:L 6002 61 2nH
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Im
FACILITY: HANES DYE & FINISHING CO. - MT HOPE PLANT
PROBLEM (S)
AGENCY
AGENCY CONTACT
TELEPHONE NO
FIRE / SHERIFF
BUNER DEPT. OF PUBLIC
CHIEF
919 - 575 - 6561
HAZMAT RESPONSE
SAFETY
WAYNE HOBGOOD
EXT 108
GRANVILLE COUNTY
EMERGENCY MANAGEMENT
DOUG LOGAN
919 - 603 - 1314
BOILER EMISSIONS OR
NC DEHNR - DAQ
GEORGE STINAGLE
919 - 571 - 4700
POLLUTION EQUIPMENT
ERNIE FULLER
919-571 -4718
FAX
ENVIRONMENTAL
L & P CORPORATE
BOB ANDERSON
417 - 358 - 8131
QUESTIONS
ENVIRONMENTAL DEPT
THERESA BLOCK
SARAJOHNSON
ENVIRONMENTAL CONSULTANT
DELTA ENVIRONMENTAL
JOHNNIE HO
864 - 627 - 8888
AIR / STORMWATER / ETC
CONSULTANTS, INC.
DON CECCARRELLI
800 - 433 - 1214
(24 HR EMER SERV TEL NO)
800 - 888 - 9193
EMERGENCIES
MOUNT HOPE PLANT
RICHARD HORTON
919 - 291 - 2057
EMERGENCY PERSONNEL
ROGER BAUCOM
919 - 575 - 6501
CHRIS HAWKS
919 - 562 - 0630
ELMER WOLF
919 - 529 - 0876
ED AYERS
919 - 529 - 0247
EMERGENCY SERVICES
WAYNE HOBGOOD
911
FIRE / POLICE / RESCUE
FIRE / POLICE / RESCUE

FACILITY: HANES DYE & FINISHING CO. - MT HOPE PLANT
PROBLEM (S)
AGENCY
AGENCY CONTACT
TELEPHONE NO
WASTEWATER SAMPLES
BUTNER PUBLIC UIILIIES
FRED DANCY
919 - 575 - 3032
CHEMICAL SPILL TO POTW
NC DEPT HEALTH AND
(UTILITIES DIRECTOR)
(TSS/CHLORIDE
HUMAN SERVICES
BETTY LAWS
919 - 575 - 3034
VIOLATIONS)
FAX
WASTEWATER SAMPLES
CAROLINA Environmental
DAVID GRAVES
919-775-1880
LABORATORIES
FAX-
919-776-5724
R & A LABS
SID CHAMPION
336 - 996 - 2841
CHEMICAL SPILLS TO
NC DEHNR - 24 HR NO
919 - 733 - 5291
CREEK OR ENVIRONMENT
NC DEHNR RALEIGH
TED CASHION
919 - 571 - 4700
BUTNER UTILITIES
FRED DANCY
919 - .575 - 3032
BUTNER PUBLIC SAFETY
CHIEF
WAYNE HOBGOOD
919 - 575- 6561
NOTE- NRC NOTIFCATION
NATIONAL RESPONSE CENTER
800 - 424 - 8802
BASED ON CHEMICAL AND
(NRC)
OUANIIIY RELEASED
CHEMICAL HAZARDS
CHEMTREC
800 - 424 - 9300
INFORMATION
CHEMICAL SPILL REQUIRING
AEI S EMER. SPILL CONTROL &
919 - 528 - 3996
COUNTERMEASURE-BUTNER
CONTRACT OR CLEAN-UP
ENVIRON. MGT. SOLUTIONS
336 - 632 - 8800

ewe. e
I P TW2
SYSTEM
TFWAT ER
mw
. . . . . . . . . . . ......... . . . . . . . .
..................................................................................
MOUNT HOI'F
PROPFRIY
FAVFRGRFATED
WFIIANDMAFA
.............................

PAGE 02
TRAINING
All personal involved in manufacturing and clean-up activities will receive
instructions on the proper handling and disposal of chemicals and clean-up
materials.
EMERGENCY RESPONSE
A. Equipment
1. Eigl}ty four (84) Fire extinguishers located throughout the plant and
checked weekly.
2. Fire hoses located throughout the plant.
3. Fire alarms tied into city fire department.
4. One hundred (100) feet of absorbent float material.
5. Five hundred (500) lbs. of absorbent material (speedy dry).
6. Goggles, aprons, rubber gloves, rubber boots, protective clothing for
cleaning up spills.
7. Variety of commercial type absorbent and containment materials.
8. Front end loader to scoop up spills or make emergency dikes.
9. Eye washes and showers
10. Acid neutralizer
11. Portable pumps
12_ POrtabl6, oye.-washes
B. PROCEDURES
1. Any employee discovering the release of any toxic or potentially hazardous
material, that is not readily controllable, must immediately notify an
Emergency Coordinator.
2. The Emergency Coordinator will assess the situation, determine if evacuation
is necessary, and notify all appropriate agencies.
3. all material and procedures readily available will be used to control and
contain any spills.
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Page K3
EMERGENCY RESPONSE (continued)
4. The two electric pumps in the pump house will be turned off, if
necessary, to prevent a slug from going to the aerated pond. All
effluent from the plant can be pumped from the sump of the pump
house into drums for proper disposal.
5. If a slug gets into the aerated holding pond, the volume control
valve will be closed to prevent it from going to the P.O.T.W.
The spill can then be treated and neutralized in the pond.
6. If an outside contractor is needed, the company listed below has
available the necessary equipment and manpower to clean-up any spills.
a. AETC PHONE: [phone]
SLUG REPORTING PROCEDURE
After any reportable incident, an emergency coozdinator.will notify the
State D.E.H.N.R. representative and local P.O.T.W., as to what occurred
and what control and containment steps are being implemented.
This plan will be continuouslyupgraded and improved upon as conditions,
procedures, and technology change.
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�., ,, i _ " 1 (SnI) 20 .61 - 'onV: 23NI I/3.LV0 SS

VANES
DYE AND FINISHING CO.
MOUNT HOPE PLANT
Telephone: 919 / 575-6501 405 West B Street • P.O. Box 209 • Butner, NC 27509 Fax: 919 / 575-6552
CC: Tom McGee, Butner Town Manager
Fred Dancy, Director of Butner Public Utilities
Chief Wayne Hobgood, Butner Public Safety
Doug Logan, Director of Granville County Emergency Management
Richard Horton, Vice President & General Manager, Mount Hope Plant
Randy Snyder, President, Hanes Dye & Finishing Company
Mark Linville, Corporate Finance Officer, Hanes Companies
Dennis Tart, Environmental Manager hares Dye & Finishing Company
Roger Baucom, Plant Engineer Mount Hope Plant
Chris Hawks, Mount Hope Plant Superintendent
A �'�COMPANY

a
ti
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0