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HomeMy WebLinkAboutNC0036196_Pretreatment_20230518City of Conover Control Authority and/or Municipality PERMIT RECEIVED Industrial User Pretreatment Permit (IUP) To Discharge Wastewater Under the MAY 18 2023 Industrial Pretreatment Program 101HS IUP Number 433.17 NCDEQ/DWR/NPDES 40 CFR Category(if Applicable) In compliance with the provisions of North Carolina General Statute 143-215.1, any applicable federal categorical pretreatment regulations, all other lawful standards and regulations promulgated and adopted by the North Carolina Environmental Management Commission, and the Control Authority and/or Municipality Sewer Use Ordinance. The following Industry, hereafter referred to by name or as the permittee: Industry name, permittee: Hickory Springs Mfg Co — Wire Technology Plant Facility Located at Street Address 1115 Farrington St city Conover state, zip North Carolina, 28613 is hereby authorized to discharge wastewater from the facility located at the above listed address into the sanitary sewer collection system and the wastewater treatment facility of the Control Authority and/or Municipality listed below: IUP Control Authority and/or Municipality WWTP name: City of Conover / Clark Creek WWTP(Newton) NPDES Number: - NC0031696 or- ()-D W WTP Address: 1407 McKay Rd City, State, Zip Newton, North Carolina 28613 in accordance with effluent limitations, monitoring requirements, and all other conditions set forth in Parts I, II, and III of this Industrial User Pretreatment Permit (IUP). Effective date, this permit and the authorization to discharge shall become effective at midnight on this date:. 05/12/2023 Expiration date, this permit and the authorization to discharge shall expire at midnight on this date: 1 05/12/2028 52> Date signed Tide Industrial User Pretreatment Permit (IUP) PART I Specific Conditions IUP, PART I, OUTLINE: A.) IUP Basic Information B.) IUP Modification History C.) Authorization Statement D.) Description of Discharges E.) Schematic and Monitoring Locations F.) Effluent Limits & Monitoring Requirements G.) Definitions and Limit Page(s) notes A. IUP Basic Information: Receiving Control Authority & WWTP name: POTW NPDES # : Conover/ Clark Creek Regional WWTP (Newton) NCO036196 IUP Name: IUP Number: Hickory Springs Mfg Co- Wire tech Plant 101HS IUP Effective date: Pipe Numbers, list all regulated pipes: 05/12/2023 001 IUP Expiration date: IUP 40 CFR # (if applicable), or N/A: 05/12/2028 433.17 B. IUP History. A Complete Permit History is required): 11 / 15/2012 Original Issuance 11/14/2017 Permit Renewal 7/25/2018 Modification Flow daily- 0.006 mg monthly ave - 0.005mg 7/25/2018 Modification Silver limit- 0.020 mg/1 daily 0.010 mg/l monthly ave Cyanide daily max typo changed to 1.20 mg/l. monthly ave 0.065 mg/1 7/25/2018 Update Update permit to most recent model IUP 5/12/2023 Renewal 2 Industrial User Pretreatment Permit (IUP) PART I Snecific Conditions C.) Authorization Statement: 1.) The Permittee is hereby authorized to discharge wastewater in accordance with the effluent limitations, monitoring requirements, and all other conditions set forth in this Industrial User Pretreatment Permit (IUP) into the sewer collection system and wastewater treatment facility of the Control Authority and/or Municipality. 2.) The Permittee is hereby authorized to continue operation of and discharge wastewater from the following treatment or pretreatment facilities. These facilities must correspond to the treatment units listed on both the application and inspection torms. IU Treatment Units List all Treatment Units: Descriptions: Diagrams included pH neutralization Tank Conical Tanks Final pH surge Tank Sludge Hopper Tank Filter Press Filter Ozone Generator 3.) The Permittee is hereby authorized to, if required by the Control Authority and/or Municipality and after receiving Authorization to Construct (A to C) from the Control Authority and/or Municipality, construct and operate additional pretreatment units as needed to meet final effluent limitations. D.) Description of IUP Discharge(s): I . Describe the discharge(s) from all regulated pipes. Pipe # 001 , Description of Discharge: Treated discharge of rinse water from Zinc Phosphate electroless wire coating process 3 Industrial User Pretreatment Permit (IUP) PART I Specific Conditions E.) Schematic and Monitoring Locations: The facility schematic and description of monitoring location(s) given below must show enough detail such that someone unfamiliar with the facility could readily find and identify the monitoring location(s) and connection to the sewer. Include and identify all regulated pipes. See attached diagrams. 4 Phes Rinse Tank Treatment Operation Hickory Springs ManuactnrIng Co. Conover, TIC pN Neutrarmallon•Tank Final pH Surge Tank W) v FS • naswry O �=rev.ISMrd, Process Flow Diagram Zinc Phosphate Conversion Coating Operation Hickory Springs Manufacturing Co. Conover, NC Clean Steel Rod Borax Pentahydrate Zinc Phosphate Concentrate Borax 9%_ 12% Hot Water Rinse Ph os Rinse Zane Rhos Conversion Ta115 F-135F T-115 F-135F TeAmbient T=115 F-135F To tanker truck for off -site dsposal To tanker truck for Notes off -she disposal All tanks piped for fresh water makeup. Each tank has a holding capacity ofa PProxlmately 4,400 gallons Sample Point Phos Rinse Treatment To tanker truck for Operation off -site disposal Discharge to City sewer I Sludge Dewatering 1 Solids to off -site disposal IUP, Part 1 Section F: Effluent Limits and Monitoring Requirements The Permittee may discharge from this specific Pipe number according to these specific dates, effluent limits, and monitoring requirements Receiving POTW name => Clark Creek IU name => Receiving POTW NPDES # _> NC0036196 IUP # _> Effective date for these Limits => 05/12/2023 Pipe # _> Expiration date for these Limits => 05/12/2028 40 CFR # _> THE LIMITS ON THIS PAGE ARE, (Check one below): LIMITS for ENTIRE permit period => X INTERIM Limits for period # 1 => INTERIM Limits for period # 2 => FINAL Limits Page => Hickory Springs Mfg - Wire tech 101HS 001 433.17 if not applicable put N/A Concentration Limits Mass Limits Monitoring Frequency Daily Max Monthly Average Units Daily Max Monthly Average Units By Industry B POTW Sample Collection Method (C or G Required Laboratory Detection Level 1 Flow 0.006 0.003 MGD daily Semi-annual C 2 BOD mg/1 3 TSS 4 Temperature 5 PH 5-12 Std units daily Semi-annual G 0.1 S.U. OTHER PARAMETERS; Please List Al habeticall 6 Chromium 2.770 1.710 Mg/1 Monthly Semi-annual C 0.01 7 Copper 0.800 0.080 Mg/1 Monthly Semi-annual C 0.025 8 Zinc 2.610 1.480 Mg/1 Monthly Semi-annual C 0.005 9 Silver 0.020 0.010 Mg/1 quarterly Semi-annual C 0.006 10 Cadmium 0.110 0.070 Mg/1 quarterly Semi-annual C 0.005 11 Lead 0.690 0.430 Mg/1 quarterly Semi-annual C 0.040 12 Nickel 0.100 0.100 Mg/1 quarterly Semi-annual C 0.013 13 Cyanide 1.200 0.065 mg/1 quarterly Semi-annual G 0.005 14 TTO 2.130 Mg/1 Semi-annual Semi-annual C/G 15 16 17 18 19 20 21 _ 22 _ 23 7 Industrial User Pretreatment Permit (IUP) PART II General Conditions G.) Definitions and Limit Page(s) notes: In addition to the definitions in the City of Conover Sewer Use Ordinance the following definitions and requirements apply: 1. Composite Sample: Unless defined differently below, a composite sample for the monitoring requirements of this IUP, is defined as the automatic or manual collection of one grab sample of constant volume, not less than 100 ml, collected every hour during the entire discharge period on the sampling day. Sampling day shall be a typical production, and discharge day. 2. Composite Sample, alternative definition: A composite sample for the monitoring requirements of this IUP is the same as described above unless specifically defined below as the automatic or manual collection of constant volume and constant time grab samples collected and composited according to the following criteria: specific volume of each grab sample = specific time interval between samples = total duration of sample collection period = Total number of grab samples to be composited = 3. Daily Monitoring Frequency Milliliters Hours Hours Samples Daily Monitoring Frequency as specified in this IUP shall mean each day of discharge. 4. Grab Sample 5. Grab sample for the monitoring requirements of this IUP, is defined as a single "dip and take" sample collected at a representative point in the discharge stream. Instantaneous measurement An Instantaneous measurement for the monitoring requirements of this IUP is defined as a single reading, observation, or measurement. Industrial User Pretreatment Permit (IUP) PART II General Conditions Outline of PART II 1. Representative Sampling 16. Federal and/or State Laws 2. Reporting 17. Penalties 3. Test Procedures 18. Need to Halt or Reduce 4. Additional Monitoring by 19. Transferability Permittee 5. Duty to comply 20. Property Rights 6. Duty to Mitigate 21. Severability 7. Facilities Operation, Bypass 22. Modification, Revocation, Termination 8. Removed substances 23. Reapplication 9. Upset Conditions 24. Dilution Prohibition 10. Right of Entry 25. Reports of Changed Conditions 11. Availability of Records 26. Construction of pretreatment facilities 12. Duty to provide information 27. Reopener 13. Signatory Requirements 28. Categorical Reopener 14. Toxic Pollutants 29. General Prohibitive Standards 15. Civil and Criminal Liability 30. Reports of Potential Problems 1. Representative Sampling Samples and measurements taken as required herein shall be representative of the volume and nature of the monitored discharge. All samples shall be taken at the monitoring points specified in this permit and, unless otherwise specified, before the effluent joins or is diluted by any other wastestream, body of water, or substance. Monitoring points shall not be changed without notification to, and approval by, the permit issuing authority. 2. Reporting a.) Monitoring results obtained by the permittee shall be reported on forms specified by the City of Conover, postmarked no later than the twentieth day of the month following the month in which the samples were taken. If no discharge occurs during a reporting period (herein defined as each calendar month) in which a sampling event was to have occurred, a form with the phrase "no discharge" shall be submitted. Copies of these and all other reports required herein shall be submitted to the Control Authority and/or Municipality and shall be sent to the following address: Andrew Evans Pretreatment Coordinator City of Conover P.O. Box 549 Conover, N.C. 28613 828-465-2279 9 Industrial User Pretreatment Permit (IUP) PART II General Conditions b.) If the sampling performed by the permittee indicates a violation, the permittee shall notify the Control Authority and/or Municipality within 24 hours of becoming aware of the violation. The permittee shall also repeat the sampling and analysis and submit the results of the repeat analysis to the Control Authority and/or Municipality within 30 days after becoming aware of the violation. 3. Test Procedures Test procedures for the analysis of pollutants shall be performed in accordance with the techniques prescribed in 40 CFR part 136 and amendments thereto unless specified otherwise in the monitoring conditions of this permit. 4. Additional Monitoring by Permittee If the permittee monitors any pollutant at the location(s) designated herein more frequently than required by this permit, using approved analytical methods as specified above, the results of such monitoring shall be submitted to the Control Authority and/or Municipality. The Control Authority and/or Municipality may require more frequent monitoring or the monitoring of other pollutants not required in this permit by written notification. 5. Duty to Comply The permittee must comply with all conditions of this permit. Any permit noncompliance constitutes a violation of the Control Authority and/or Municipality Sewer Use Ordinance and is grounds for possible enforcement action. 6. Duty to Mitigate - Prevention of Adverse Impact The permittee shall take all reasonable steps to minimize or prevent any discharge in violation of this permit which has a reasonable likelihood of adversely affecting human health, the POTW, the waters receiving the POTW s discharge, or the environment. 7. Facilities Operation, Bypass The permittee shall at all times maintain in good working order and operate as efficiently as possible, all control facilities or systems installed or used by the permittee to achieve compliance with the terms and conditions of this permit. Bypass of treatment facilities is prohibited except when approved in advance by the Control Authority and/or Municipality. Bypass approval shall be given only when such bypass is in compliance with 40 CFR 403.17. 8. Removed Substances Solids, sludges, filter backwash, or other pollutants removed in the course of treatment or control of wastewaters shall be disposed of in a manner such as to prevent any pollutants from such materials from entering the sewer system. The permittee is responsible for assuring its compliance with any requirements regarding the generation, treatment, storage, and/or disposal of "Hazardous waste" as defined under the Federal Resource Conservation and Recovery Act. 10 Industrial User Pretreatment Permit (IUP) PART II General Conditions 9. Upset Conditions An "upset" means an exceptional incident in which there is an unintentional and temporary noncompliance with the categorical standards of this permit because of factors beyond the reasonable control of the permittee. An upset does not include noncompliance to the extent caused by operational error, improperly designed or inadequate treatment facilities, lack of preventative maintenance, or careless or improper operations. An upset may constitute an affirmative defense for action brought for the noncompliance. The permittee has the burden of proof to provide evidence and demonstrate that none of the factors specifically listed above were responsible for the noncompliance. 10. Right of Entry The permittee shall allow the staff of the State of North Carolina Department of Environment and Natural Resources, Division of Water Quality, the Regional Administrator of the Environmental Protection Agency, the Control Authority and/or Municipality, and/or their authorized representatives, upon the presentation of credentials: 1. To enter upon the permittee's premises where a real or potential discharge is located or in which records are required to be kept under the terms and conditions of this permit; and 2. At reasonable times to have access to and copy records required to be kept under the terms and conditions of this permit; to inspect any monitoring equipment or monitoring method required in this permit; and to sample any discharge of pollutants. 11. Availability of Records and Reports The permittee shall retain records of all monitoring information, including all calibration and maintenance records as well as copies of reports and information used to complete the application for this permit for at least three years. All records that pertain to matters that are subject to any type of enforcement action shall be retained and preserved by the permittee until all enforcement activities have concluded and all periods of limitation with respect to any and all appeals have expired. Except for data determined to be confidential under the Sewer Use Ordinance, all reports prepared in accordance with terms of this permit shall be available for public inspection at the Control Authority and/or Municipality. As required by the Sewer Use Ordinance, effluent data shall not be considered confidential. 12. Duty to Provide Information The permittee shall furnish to the Director of Public Works or his/her designees, within a reasonable time, any information which the Director, his/her designee, or the Division of Water Quality may request to determine whether cause exists for modifying, revoking and reissuing, or terminating this permit or to determine compliance with this permit. The permittee shall also furnish, upon request, copies of records required to be kept by this permit. 13. Signatory Requirements All reports or information submitted pursuant to the requirements of this permit must be signed and certified by the Authorized Representative as defined under the Sewer Use Ordinance. If the designation of an Authorized Representative is no longer accurate because a different individual or 11 Industrial User Pretreatment Permit (IUP) PART II General Conditions position has responsibility for the overall operation of the facility, or overall responsibility for environmental matters for the company, a new authorization satisfying the requirements of this section must be submitted to the Conover Pretreatment Coordinator prior to or together with any reports to be signed by an authorized representative. 14. Toxic Pollutants If a toxic effluent standard or prohibition (including any schedule of compliance specified in such effluent standard or prohibition) is established under Section 307(a) of the Federal Clean Water Act for a toxic pollutant which is present in the discharge and such standard or prohibition is more stringent than any limitation for such pollutant in this permit, this permit may be revised or modified in accordance with the toxic effluent standard or prohibition and the permittee so notified. 15. Civil and Criminal Liability Nothing in this permit shall be construed to relieve the permittee from civil or criminal penalties for noncompliance. 16. Federal and/or State Laws Nothing in this permit shall be construed to preclude the institution of any legal action or relieve the permittee from any responsibilities, liabilities, or penalties established pursuant to any applicable Federal and/or State law or regulation. 17. Penalties The Sewer Use Ordinance of the Control Authority and/or Municipality provides that any person who violates a permit condition is subject to a civil penalty not to exceed $25,000 dollars per day of such violation. Under state law, (NCGS 143-215.6B), under certain circumstances it is a crime to violate terms, conditions, or requirements of pretreatment permits. It is a crime to knowingly make any false statement, representation, or certification in any record or other document submitted or required to be maintained under this permit, including monitoring reports or reports of compliance or noncompliance. These crimes are enforced at the prosecutorial discretion of the local District Attorney. 18. Need to Halt or Reduce not a Defense It shall not be a defense for a permittee in an enforcement action that it would have been necessary to halt or reduce the permitted activity to maintain compliance with the conditions of the permit. 19. Transferability This permit shall not be reassigned or transferred or sold to a new owner, new user, different premises, or a new or changed operation without approval of the Town. 20. Property Rights This permit does not convey any property rights in either real or personal property, or any exclusive privileges, nor does it authorize any injury to private property or any invasion of personal rights, nor any infringement of Federal, State or local laws or regulations. 12 Industrial User Pretreatment Permit (IUP) PART II General Conditions 21. Severability The provisions of this permit are severable and, if any provision of this permit or the application of any provision of this permit to any circumstance is held invalid, the application of such provision to other circumstances and the remainder of this permit shall not be affected thereby. 22. Permit Modification, Revocation, Termination This permit may be modified, revoked and reissued or terminated with cause in accordance to the requirements of the Control Authority and/or Municipality Sewer Use Ordinance and North Carolina General Statute or implementing regulations. 23. Re -Application for Permit Renewal The permittee is responsible for filing an application for reissuance of this permit at least 180 days prior to its expiration date. 24. Dilution Prohibition The permittee shall not increase the use of potable or process water or in any other way attempt to dilute the discharge as a partial or complete substitute for adequate treatment to achieve compliance with the limitations contained in this permit. 25. Reports of Changed Conditions The permittee shall give notice to the Control Authority and/or Municipality of any planned significant changes to the permittee's operations or system which might alter the nature, quality, or volume of its wastewater at least 180 days before the change. The permittee shall not begin the changes until receiving written approval from the Control Authority and/or Municipality. Also see Part Il, 30 below for additional reporting requirements for spill/slug issues. Significant changes may include but are not limited to (a) increases or decreases to production; (b) increases in discharge of previously reported pollutants; (c) discharge of pollutants not previously reported to the Control Authority and/or Municipality; (d) new or changed product lines; (e) new or changed manufacturing processes and/or chemicals; or (f) new or changed customers. 26. Construction No construction of pretreatment facilities or additions thereto shall be begun until Final Plans and Specifications have been submitted to the Control Authority and/or Municipality and written approval and an Authorization to Construct (A to C) have been issued. 13 Industrial User Pretreatment Permit (IU PART II General Conditions 27. Reopener The permit shall be modified or, alternatively, revoked and reissued to comply with any applicable effluent standard or limitation for the control of any pollutant shown to contribute to toxicity of the WWTP effluent or any pollutant that is otherwise limited by the POTW discharge permit. The permit as modified or reissued under this paragraph may also contain any other requirements of State or Federal pretreatment regulations then applicable. 28. Categorical Reopener This permit shall be modified, or alternatively, revoked and reissued, to comply with any applicable effluent standard or limitation issued or approved under Sections 302(b)(2)(C) and (D), 304(b)(2), and 307(a)(2) of the Clean Water Act, if the effluent standard or limitation so issued or approved: 1.) contains different conditions or is otherwise more stringent than any effluent limitation in this permit; or 2.) controls any pollutant not limited in this permit. The permit as modified or reissued under this paragraph shall also contain any other requirements of the Act then applicable. 29. General Prohibitive Standards The permittee shall comply with the general prohibitive discharge standards in 40 CFR 403.5 (a) and (b) of the Federal pretreatment regulations. 30. Potential Problems The permittee shall provide protection from accidental and slug discharges of prohibited materials and other substances regulated by this permit. The permittee shall also notify the POTW immediately of any changes at its facility affecting the potential for spills and other accidental discharge, discharge of a non -routine, episodic nature, a non -customary batch discharge, or a slug load as defined in the Sewer Use Ordinance. Additionally, the permittee shall notify by telephone the Control Authority and/or Municipality immediately of all discharges that could cause problems to the POTW including any slug loadings as defined in the Sewer Use Ordinance. If the permittee experiences such a discharge, they shall inform the Control Authority and/or Municipality immediately upon the first awareness of the commencement of the discharge. Notification shall include location of the discharge, type of waste, concentration and volume if known and corrective actions taken by the permittee. A written follow-up report thereof shall be filed by the permittee within five (5) days, unless waived by the Control Authority and/or Municipality. 14 Industrial User Pretreatment Permit (IUP) PART III Special Conditions Slug/Spill Control measures The permittee shall provide updates to the Control Authority as required as required by Part II, 30, of this IUP. Modifications to the measures shall be approved by the Control Authority prior to installation/implementation. If a measure fails, The Control Authority shall be notified within 24 hours. 2. Sludge Management Plan Ninety days prior to the initial disposal of sludge generated by any pretreatment facility, the permittee shall submit a sludge management plan to the Control Authority. 3. Flow Measurement Requirements (For SIUs with discharge flow meters) The permittee shall maintain appropriate discharge flow measurement devices and methods consistent with approved scientific practices to ensure the accuracy and reliability of measurements of the volume of monitored discharges. Devices installed shall be a continuous recording flow meter capable of measuring flows with a maximum deviation of less than 10% from true discharge rates throughout the range of expected discharge volumes. The devices shall be installed, calibrated, and maintained to ensure accuracy. At the time of issuance of the permit, this method consists of a water flow meter, make- Allen Bradley, model Panelview Plus 400. The meter shall ne calibrated annually. The meter shall be calibrated annually. Modifications to the flow metering equipment shall be approved by the Control Authority prior to installation. If a required flow measurement device fails, the Control Authority shall be notified within 24 hours. 4. Certified Laboratory Analysis Pollutant analysis shall be performed by a North Carolina Division of Water Quality Certified Laboratory that is certified in the analysis of the pollutant in wastewater. 5. Operator in Charge Hickory Springs Mfg -Wire Tech Plant must designate a competent person to be in responsible charge of the operation and maintenance of the pretreatement facilities. A backup personnel shall be designated to be responsible in the occasion of the absence of the person in responsible charge. These persons must be identified in writing by name or job title within 30 days of the beginning of discharge to the City of Conover. On the occasion of a change in the primary or backup operator, a notification of personnel replacement must be submitted in 15 Industrial User Pretreatment Permit (IUP) PART III Special Conditions writing to the City of Conover within 30 days. A responsible, assigned operator must be on site whenever the pretreatment facility is discharging. 6. Total Toxic Organics (TTO) Definition "TTO", or Total Toxic Organics, is the sum of the concentrations of the toxic organic compounds listed in 40 CFR that are found in the permittee's process discharge at a concentration greater than 0.01 mg/l. 7. Total Toxic Organics (TTO) Certification In lieu of monitoring for TTO, the permittee may, upon submitting to the Control Authority one sample showing TTO compliance and a toxic organic management plan, make the following certification every six months: "Based upon my inquiry of the person or persons directly responsible for managing compliance with the permit limitation for total toxic organics (TTO), I certify that, to the best of my knowledge, no dumping of concentrated toxic organics into the wastewaters has occurred since filing of the last monitoring report. I further certify that this facility is implementing the toxic organic management plan submitted to the Control Authority." At a minimum, the certification statements are due by June 30t' of each year covering the January through June six month period, and December Th of each year covering the July through December six month reporting period. If the certification is not submitted for both periods within 7 days of the respective due dates, the Control Authority shall collect TTO samples before December 31 {and the permittee may be billed for the cost of the TTO sampling and/or analysis. 8. Toxic Organic Management Plan Within ninety days of the issuance of this permit, the permittee shall develop and submit to the Control Authority a toxic organic management plan. 9. Duty to Maintain It is the obligation of Hickory Springs Manufacturing Co to maintain all equipment necessary to meet permit requirements. Upon discovery of equipment failures, which may lead to permit violation, all discharge shall be ceased until repairs are completed. f[i IUP Synopsis IUP Basic Information Receiving POTW name: POTW NPDES#: Clark Creek Regional WWTP Newton NCO036196 IUP name: IUP Number: Hickory Springs Wire Tech Plant 101HS IUP Effective date: Pipe Numbers, list all regulated pipes: 05/12/2023 001 IUP expiration date: IUP 40 CFR#, if applicable: 05/12/2028 433.17 A. IUP Survey & Application form Attach a completed copy of the Industrial User Wastewater Survey & Application Form (see appendix 6-A) B. IU Inspection form Attach a copy of an Industrial User Inspection Form (see chapter 7) completed by the Control Authority within the past 12 months. C. RATIONALE FOR LIMITATIONS: As listed on the IUP Limits Page(s), PART I, Section F of the IUP. All parameter limits are calculated to protect the POTW from pass through and inhibition and to allow the beneficial use of biosolids generated by the WWTP. These limits do not result in over allocation of the POTW's treatment capacity. Limits are achievable with standard tech SIU INSPECTION FORM Name Of Industry: HSM Solutions .- V We 4,ecL oictoj— Address Of Industry: 1115 Farrington St Conover_ N(' 28613 Industry Representatives: IUP # 101 HS IUP Expiration Date: Title Ma ) IeL_ Q &4." POTW Representatives: Title Andrew Evans City of Conover Pretreatment Coordinator Date Of Inspection: 2' q 2 z! i Time Of Inspection: c? e! 0 6 all/pm Purpose of Inspection: Annual Othhr�Describe) N POTW to which IU discharges e w t-j t NPDES # Al i_ao Is SIU currently in SNC? , If yes, for Nvhat'? PART I - INITIAL INTERVIEW Has anything changed since the last inspection or IUP application in the following: COMMENTS Product YES / Raw materials used YES Manufacturing processes YES Categorical, if applicable YES N Production rate YES / Number of employees � / O Number of shifts YES / > Comments: PART II - PLANT TOUR - Visit all areas where wastewater is generated or where there are drains to the POTW. Plant Tour Section A - PRODUCTION AND STORAGE AREAS 1. Are there tour drains in the production area? YES /(g Where do they go? 2. Are production areas diked, conta' , or otherwise constructed in such a way as to prevent harm to the WWTP, especially from spills or slugs? S O Comments: Ire - h_ A:Q_ t- 4j.A;:: 3. Are there floor drains in the storage area? Where do they go? 4. Are storage tanks and areas diked, contain d, or otherwise constructed in suchwa way as to prevent harm to the WWTP, especially from spills or slugs? O/ NO Comments: TO Rot 5. Are process and storage tanks and pipes labeled? / NO, 6. How are off -spec raw materials, and products dispose of? 7. When is the production area cleaned? 10 ki Sw� 8. Is the wastewater from cleaning the produc area- disch 9. What non -process wastewaters are discharged to POTW? Comments: Title: SIU Inpsection Fomt File name: COMP.INSP App 7-D Revision data: August 1, 1994 Page 1 SILT INSPECTION FORM PART II - Plant Tour Section B - PRETREATMENT SYSTEM Ask the operator to describe pretreatment system. 1. Does operator seem knowledgable about the system? ES NO Comments: 2. Are all units operational? / NO 3. How often does operator/maintenance • n check system?i 4. Is there an operator for each shift? ES NO 5. How and when is sludge disposed of? l� 6. Is there a schedule for preventative maintenance? / NO 1.,- ,�• Comments: Evaw y 5'1 F wtCAP- i, i1 4L'I c y PART 11 - Plant Tour Section C - SAMPLING POINT(S) AND FLOW MEASUREMENT (Collect a sample if desired.) 1. Does an outside lab complete sampling? �/ NO If yes, name of lab. ea" (.-�)Vf 5 2. If industry completes sampling, ask the industry representative to describe sampling procedures. Comments: 3. Is flow measurement equipment operational? OP NO Comments: 4. Is there a calibration log for the flow meter? Y / NO Comments: 0ACL a voGt/ �5,�,�#-er 5r�/1—L Comments: PART III - EXIT INTERVIEW Review monitoring records andpO.e,r SILT records required by iUP. 1. Are files well organized? (jEV NO Comments: 2. Are sample collection / chain -of -custody forms filled out property? NO Comments: 3. Do results in files agree with reports sent to POTW? ep(40Comments: 4. Who has authority to shutdown production should a spill or slug discharge occur? does SIU inform employees of whom to call at POTW in case of spill/slug? r if sl g/spill plan is already required by POTW review procedures. 6. Is STU implementing slug/spill plan? NO Comments: Comments: INSPECTION RESULTS Slug/Spill Control Plan Needed? YES / NO Comments, Required Or Recommended Actions: (Ummerd s nn Title: SIU Inpsection Form Filename: COMRINSP App 7-D Revision data: August 1, 1994 Page 2 1 + . L SIU INSPECTION FORM Signature Of Inspectors) ��-�t' _ Date: a - a3-,,2,-- 7 ` Z/ 40 Date: 1- •2 1 .l ci ck 5 Ve"/e• \T c jb �S l/" L �' i Q U A �5,� f r �- V�, �O w awd (,fU:c Qvk +,> acae Title: SIU Inpsection Form Filename: COMP.INSP App 7-D Revision data: August 1, 1994 Page 3 r IUP Synopsis A. IUP Basic Information Receivin; POT%k name. POTR' NPDES t Clark Creek WWTP NCO031696 lUP Nxmc . 1UP Number: Hickory Springs Mfg Co - Wire Technology Plant 101 HS tUP Effective due Pipe Numbers. list all mpimed pipes: 05/12/2023 001 lUP Expiration date: 1UP 40 CFR A. if applicable. 05/12/2028 433.17 B. IU Survey & Application form Attach a completed copy of the Industrial User Wastewater Survey & Application Form (see appendix 6-A). C. IU Inspection form Attach a copy of an Industrial User Inspection Form (see chapter 7) completed by the Control Authority within the past 12 months. D. RATIONALE FOR LIMITATIONS: as listed on the IUP Limits Page(s), PART I, Section F of the IUP. RATIONALE # 1: Review of IU Monitoring Data, with no Over Allocation situation: The following pollutants were assigned numerical limits in this IUP based on a review of monitoring data for the permittee to determine what range of concentrations are currently being discharged. To account for sample variability a factor was applied to the monitoring data to determine the permit limit. Permit limits assigned by the Local IUP Control Authority can not result in an Over Allocation situation for any pollutants. Limits are based on previous IUP and no changes are needed RM # Synopsis Page: t IUP Synopsis RATIONALE # 2: Categorical Industrial Limits, with no Over Allocation situation Check here if Combined wastestream Formula (OWT) was used. If used, please attach calculations: (see CHAT Spreadsheet, Appendix 6-F) was used was not used x The following pollutants were assigned numerical limits in this IUP based on the categorical regulations. These limits do not result in over allocations. EPA Title 40 CFR 433.17 Cadmium, Chromium Copper, Lead, Nickel, Silver, Zinc, Cyanide, TTO RATIONALE # 3a: Over Allocation Prevention, with IU pollutant reduction The following pollutants were assigned numerical limits in this IUP based on allocating the Maximum Allowable Industrial Loading (MAIL) determined with the Headworks Analysis (HWA) among all Industrial Users. The total loading of each pollutant from all permitted discharges does not exceed the MAIL. These limits do not result in over allocations. N/A RATIONALE # 3b: Interim Limits for IU pollutant reduction: The following pollutants were assigned interim numerical limits in this IUP to allow time for the industry to come into compliance with final limits which will not result in over allocations. IUP # Synopsis Page: 2 IUP Synopsis RATIONALE # 4: 4.) Other Rationale for Limitations: The follo%;Jaz basis was used for develo inz TUP Limits: N/A 11 and was applied to the following pollutants: N/A RATIONALE # 5: No Limit needed or assigned in an IUP: The following pollutants were not assigned numerical limits in this IUP because the loadings for these pollutants from this IU was less than 5 % of the MARL. The loading of these pollutants from this IU is considered insignificant at this time. Iu ant, % of the MARL M IUP M Synopsis Page: 3 INDUSTRIAL USER WASTEWATER SURVEY AND DISCHARGE PERMIT APPLICATION The information provided on this questionnaire serves two functions: To determine if your facility is in need of a Significant Industrial User (SIU) Industrial User Pretreatment Permit (IUP) for the discharge of wastewater to the Publicly Owned Treatment Works (POTW) sanitary sewer system. 2. If a SIU IUP is required, this survey shall serve as the application for that IUP and the information will be used to issue the IUP. PLEASE REFER TO THE GUIDANCE FOR COMPLETING THE INDUSTRIAL USER SURVEY/APPLICATION INSTRUCTIONS, AVAILABLE AT: http:llportal.ncdenr.org/web/wq/swp/ps/pret/permwrite STATUS of APPLICANT / APPLICATION - PLEASE CHECK ONE [ ] New Permit for Proposed Discharge Anticipated Date of initial process wastewater discharge [ ] Existing Unpermitted Discharge [ X ] Permit Renewal for Existing SIU Permit, existing non-SIU permit, or other written permission from POTW. Note If this application requests a greater amount of wastewater discharge [flow], a greater amount of pollutant discharge or a discharge of different pollutants than specified in the last wastewater permit application for this facility, or any other significant changes, please indicate this as needed in the applicable Questions, especially Questions A8 and ET Note to Signing Official: In accordance with Title 40 of the Code of Federal Regulations Part 403.14, information and data provided in this questionnaire which identifies the content, volume, and frequency of discharge shall be available to the public without restriction. Requests for confidential treatment of other Information shall be governed by procedures specified in 40 CFR Part 2. This is to be signed by the Authorized Representative of your firm, as defined in 40 CFR Part 403.12 (1) and (YOUR SUO CITATION), after adequate completion of this form and review of the information by the signing representative. I, Sam R. Gibbs Operations Manager certify under penalty of law that this document and all attachments were prepared under my direction or supervision in accordance with a system designed to assure that qualified personnel properly gather and evaluate the information submitted. Based on my inquiry of the person or persons who manage the system, or those persons directly responsible for gathering the information submitted is, to the best of my knowledge and belief, accurate and complete. I am an authorized representative of the user and am authorized to execute this certification on behalf of the user, I am aware that there are significant penalties for submitting false information in violation of this certification, including the possibility of fines and/or imprisonment. I also certify that I have completed the necessary notification as required by the POTW to document my qualification as an Authorized Representative as set f rth in 40 CFR Part 4 .12 1) and (YOUR SUO CITATION). r ;It Date Signature of Representative (Seal, if applicable) Please return this survey to: Eric Williams Asst. Public Utilities Director PO Box 549 City of Conover, North Carolina 28613 IUP Application_blank_apr_2012 Page 1 of 21 INDUSTRIAL USER WASTEWATER SURVEY AND DISCHARGE PERMIT APPLICATION SECTION A — GENERAL INFORMATION For the production or manufacturing facility for which this application is being completed: Facility name Hickory S rin s Mfg. Co. — Wire Technology Plant Physical address 1101 Farrin on St Conover NC 28613 Mailing address if different P.O. Box 128 Hickory, NC 28603 General Telephone Number 828-328-2201 General Fax Number Website 2. If applicable, general information about the corporate office, parent company, etc. [ ] N/A Company name Hickory Springs Manufacturing Company Physical address 235 2nd Ave. NW, Hickory, NC 28601 Mailing address if different P.O. Box 128 Hickory,NC 28603 General Telephone Number 828-328-2201 General Fax Number Website I https://www.hsmsolutions.com/ Primary Authorized Representative authorized to represent this firm in official dealings with the Publicly Owned Treatment Works (POTW). Name Sam Gibbs Title Operations Manager Telephone/Cell/Fax 828-328-2213 Ext. 4320 Email srgibbs@hsmsolutions.com Primary work location: X Facility _Corporate Office Other— List address here: 4. Alternate Authorized Contact for when the Primary Authorized Representative is not available. Name Zenaida Camacho Title EHS Manager Telephone/Cell/Fax 828-328-2213 Ext. 3125 Email zcamacho hsmsolutions.com Primary work location: Facility X Corporate Office Other — List address here: 5. On -Site Contact. If neither person identified in items 3 and 4 above are located at the production or manufacturing facility for which this application is being completed provide an on -site contact person available to answer questions regarding statements made on this survey as well as conduct a walkthrough of the facility: Name David Clontz Title Plant Manager Telephone/Cell/Fax 828-328-2213 Ext. 4701 Email dtclontz@hsmsolutions.com IUP Application_blank—apr_2012 Page 2 of 21 INDUSTRIAL USER WASTEWATER SURVEY AND DISCHARGE PERMIT APPLICATION SECTION A — GENERAL INFORMATION - continued 6. Identify the general type of manufacturing, production and/or service(s) conducted at the site (i.e. electroplating, printing, painting, food processing, warehousing, meat packing, machine shop, etc.). Greater detail to be provided in question A. 7. Steel Wire Provide a detailed narrative description of the manufacturing/production process(es) and/or service activities identified in question A. 6. and conducted at the facility identified in question A. 1. Wire Tech Process manufactures drawn steel wire from steel rod stock. Some wire produced by a hard drawing process is coated with zinc using an electroless process 8. Are any process changes or expansions planned during the next five years? [ ] Yes [ X ] No If yes, describe the nature of the planned changes or expansions. As needed, clarify if answers to other application questions are for before or after the change/expansion. If the facility has an existing permit, indicate if these changes could or will result in the facility requesting changes to their existing permit. 9. List the Standard Industrial Classification Number(s) (SIC #) or North American Industry Classification System (NAICS) codes for your facility. If listing more than one code, indicate the percentage of production. SIC/NAICS code: 3315 / 331222 Percentage of production 100% 10. In what month and year were the facility's operation(s) at this location (as specified in A. 7. above) established and under what name? Facility Name Month I Year Hickory Springs Mfg. Co. — Wire Technology Plant I November 1 1996 11. Has your facility undergone any changes in licensed ownership since the date noted in question A. 10? [ ] Yes [ X ] No If yes, complete table. Facility Name Month Year IUP Application_blank_apr_2012 Page 3 of 21 INDUSTRIAL USER WASTEWATER SURVEY AND DISCHARGE PERMIT APPLICATION Section B — Flow Diagram/Schematics, Site Layout, and Pretreatment System Flow Diagram [ See the Guidance Document for Completing the Industrial User Wastewater Survey and Discharge Permit Application available at: http://portal.ncdenr.org/webtwq/swp/ps/pret/permwritel PRODUCTION/PROCESS SCHEMATIC FLOW DIAGRAM (REQUIRED) IUP Application—blank_apr 2012 Page 4 of 21 INDUSTRIAL USER WASTEWATER SURVEY AND DISCHARGE PERMIT APPLICATION Section B — Flow Diagram/Schematics, Site Layout, and Pretreatment System Flow Diagram [ See the Guidance Document for Completing the Industrial User Wastewater Survey and Discharge Permit Application available at: http://portal.nedenr.org/web/wq/Swp/ps/pret/permwrite] PLANT SITE LAYOUT (REQUIRED) -Support columns Q-Emergency Lights IUP Application—blank_apr_2012 Page 5 of 21 INDUSTRIAL USER WASTEWATER SURVEY AND DISCHARGE PERMIT APPLICATION Section B — Flow Diagram/Schematics, Site Layout, and Pretreatment System Flow Diagram [ See the Guidance Document for Completing the Industrial User Wastewater Survey and Discharge Permit Application available at: http://portal.ncdenr.org/web/wq/swp/ps/pret/permwritel WASTEWATER PRETREATMENT SYSTEM FLOW DIAGRAM {IF APPLICABLE} Process Row. Diagram Zinc Phosphate Conversion Coating Operation Hiclicory50ririgs Manufacturing Co. Conovar, NC p.yn5faatAad " • 7fia PAasChata GoouatMs lo.ix fa+tatrydrah . Iena NaitL4aWA[an 2hot11Gtc+ Aatlp4eiConvcisba ���' 7•MnKat C=3iSf-1SST ' ' T.x15f—iliR sf—l"It o tynftw tra�l7c (vr io 4nk�ctwep !or e4rtiy dtspwal elfnShd[spossl � f.apb Potat ANtavlay'pe4{vrhtcAvn�rnaksup• PhetR4paTc�Mfasht _ _5[�.-- pd�m�tlixalvAtoiapediyQrW-' d*4/tODV4#- pp� JL,J • To tankp lNOklm `• qfl-fitsdEspopJ �� ° D'ue(lxp +o tRy SA�rif • daY7tff�1{ [ ' foIlN100I/gW • difpasal IUP Application_blank_apr_2012 Page 6 of 21 INDUSTRIAL USER WASTEWATER SURVEY AND DISCHARGE PERMIT APPLICATION SECTION C — FACILITY OPERATION CHARACTERISTICS Office/Administrative Staff Monday Tuesday Wednesda ]_Thursday FridaySaturdaySunda # Employees 10 10 10 _ 10 10 Start/End Time _ 8:00 AM 5:00 PM 8:00 AM 5:00 PM 8:00 AM 5:00 PM 8:00 AM 5:00 PM 8:00 AM 1 5:00 PM Production Staff Monday Tuesday Wednesday Thursday Friday Saturday Sunday 1st Shift # Employees 30 30 30 30 30 30 30 Start Time 6:00 AM 6:00 AM 6:00 AM 6:00 AM 6:00 AM 6:00 AM 6:00 AM End Time 6:00 PM 6:00 PM 6:00 PM 6:00 PM 6:00 PM 6:00 PM 6:00 PM 2od Shift # Employees 28 28 28 28 _ _ 28 28 28 Start Time 6:00 PM 6:00 PM 6:00 PM _ 6:00 PM 6:00 PM_ 6:00 PM 6:00 PM End Time 6:00 AM 6:00 AM 6:00 AM 6:00 AM 6:00 AM 6:00 AM 6:00 AM is' Shift # Em loyees 18 18 18 18 18 Start Time 7:00 AM 7:00 AM 7:00 AM 7:00 AM 7:00 AM End Time 3:00 PM 3:00 PM 3:00 PM 3:00 PM 3:00 PM 2n° Shift # Employees 9 9 9 9 9 Start Time 3:00 PM 3:00 PM 3:00 PM 3:00 PM 3:00 PM End Time 11:00 PM 11:00 PM 1 11:00 PM 11:00 PM 1 11:00 PM 3� Shift # Employees 9 9 9 9 9 Start Time 11:00 PM 11:00 PM I 11:00 PM 11:00 PM i 1:00 PM End Time 7:00 AM 7:00 AM 1 7:00 AM 7:00 AM 7:00 AM Shift Activities — When is pretreatment done or Producing the water? SHIFT DESCRIPTION OF SHIFT ACTIVITIES Monday 1St 2nd Waste stream is run on nightshift 4 m to lam (nightshift maintenance 3rd Tuesday 1st 2nd _ Waste stream is run on nightshift 4 m to 1 am (nightshift maintenance 3rd - Wednesday 1st 2nd Waste stream is run on nightshift 4 m to 1 am (nightshift maintenance 3rd Thursday 1 St 2nd Waste stream is run on nightshift 4 m to 1 am ni htshift maintenance 3rd Friday 1 st 2nd Waste stream is run on nightshift 4 m to 1 am ni htshift maintenance 3rd Saturday 1 St _ 2nd 3rd Sunday 111 2nd 3rd IUP Application_blank_apr 2012 Page 7 of 21 INDUSTRIAL USER WASTEWATER SURVEY AND DISCHARGE PERMIT APPLICATION SECTION D — PROCESS INFORMATION NOTE: The following information must be completed for each product line. Please make copies of this page if necessary. Information revealed in this section may be held confidential and proprietary under 40 CFR 403.14 at the request of the Industrial User and the approval of the POTW. The request for confidentiality must be made at the time of the initial submission of the application. Should such a request be made and accepted in compliance with {YOUR SUO CITATION}, these page(s) will be removed before review by any non -regulatory personnel. 1. Principal product(s) produced: Steel Wire 2. Raw materials and process additives used: (1) Steel Rod; (2) Zinc -Phosphate Solution; (3) Borax pentahydrate 3. Maximum and average production rate of this particular product line (please specify units being reported): Average Production Rate Maximum Production Rate Units 19,250 lbs. per hour 24,500 Ibs, per hour I Lbs. 4. The production process is [ X ] Batch [ ] Continuous If batch, please enter the average number of batches per 24 hours. [ ] If both, please enter % or production [ 100 %] Batch [ %] Continuous 5. R 7 Days and hours of operation for this product line: From: 6 to 6 Days and Hours of discharge for this product line: From: 6 to 6 Is production subject to seasonal variation? [ ] Yes [ X ] No If yes, briefly describe the seasonal production cycles: IUP Application_blank_apr 2012 Page 8 of 21 INDUSTRIAL USER WASTEWATER SURVEY AND DISCHARGE PERMIT APPLICATION SECTION E —WATER USE AND WASTEWATER DISCHARGE INFORMATION Please indicate source(s) of water used at your facility: Source Type Check One 1f es,... Well [ j Yes [X j No How many are there? How many are in use at this time? City [X]Yes [ ] No List all Account numbers: 05-001961-003 Surface Water [ ] Yes [ X ] No Identify the source: Other [ ] Yes [ X ] No Explain: 2. Does this facility provide any treatment to the incoming water to improve the water quality prior to its use in the facility, (i.e. deionization, reverse osmosis, ultra filtration, pH adjustment, etc.)? [ ] Yes [ X ] N If yes, complete table. Treatment Process Chemicals Used Wastewater Generated and Volume d 3. This facility uses water for the following: (Please record "n/a" if the application/use does not apply to the operations at your facility.) Detailed Description of Maximum Average [E]stimated Type of Application ]Use Applicable Operation(s) Volume Volume or and/or Equipment Used Used [M]easured (gallons/day) allons/da Process 4320 4320 [XI E [ M Water Into Product n/a E M Process Related Facility/Equipment Negligible [X] E [ ] M Washdown* Process Contact Cooling or Warming n/a [ 1 E [ ] M Water Process Related Air -Pollution Control n/a [ ] E [ ] M Unit Process Related Employee Showers n/a E M Lab n/a E J M Maintenance Shop n/a E M Boilers (Please specify if live and/or dry n/a [ ] E [ ] M steam is used. Backwash Water n/a f I E I M Pump Sealant Water n/a E M General Facility/Equipment Washdown* Negligible X E M Other non -contact water uses: boilers; Boiler cooling tower 7200 4320 [X] E [ ] M non -contact cooling/warming water, blowdown general air conditioning, cooling towers, chillers, HVAC, etc. Domestic (e.g. restroom(s), non -process 317 317 [X] E [ ] M related employee showers, cafeteria, kitchen, breakroom etc. Other, please describe Evaporative losses from Balance Balance [X] E [ ] M coolingtowers Total 23,850 20,970 *Please document clean up schedules in Shift activities in Section C. IUP Application_blank_apr_2012 Page 9 of 21 INDUSTRIAL USER WASTEWATER SURVEY AND DISCHARGE PERMIT APPLICATION SECTION E — WATER USE AND WASTEWATER DISCHARGE INFORMATION (continued) 4. The facility generates wastewater from the following areas and that water is discharged where If the source of wastewater discharged does not exist at your facility record "n/a". If there is no discharge from the applicable source, record "no discharge". Wastewater is Source of Wastewater Discharged Pretreated? Volume Estimated (E) or To Where Discharged Measured (M) (gallons/day) a. Process Sanitary sewer X1 yes L I no 403 X E [X1 M b. Water Into Product n/a yes no JE M c . Process Related Sanitary sewer [ ] yes [ ] no Negligible [X] E [ ] M Facility/Equipment Washdown* d. Process Contact Cooling n/a [ ] yes [ ] no [ ] E [ ] M or Warming Water e. Process Related Air- n/a [ ] yes ( J no [ ] E [ ] M Pollution Control Unit f. Process Related n/a ( J yes [ ] no [ ] E [ ] M Employee Showers Lab n/a no E M h. Maintenance Shopn/a no E M i. Backwash Water n/a no Wes E M J. Pum Sealant Water n/a no E M k. General [ ] no Negligible [X] E [ ] M Facility/Equipment Washdown* I. Other non -contact water [ ] yes [X] no 4320 [X] E [ ] M uses: boilers; non -contact cooling/warming water, general air conditioning, cooling towers, chillers, HVAC etc. m. Domestic (e.g. Sanitary sewer [ J yes [X] no 317 [X] E [ ] M restroom(s), non -process related employee showers, cafeteria, kitchen, breakroom etc. n. Groundwater/Remediated N/A [ ] yes [ ] no [ ] E [ ] M Groundwater o. Storm Water Runoff N/A yes no 1E I M p. Tank Bottoms N/A yes no E M q.Other, please specify Evaporation yes I no Balance E M r. Total Discharged to 20,970 POTW *Please document clean up schedules in Shift activities in Section C. 5. Identify the daily maximum flow limit requested. Please explain any differences between the requested flow limit and actual flows listed in E. 4. Requested Dail Maximum Flow Limit, d: 1 6000 0.006 MGD Requested Monthly Average Flow Limit d: 30 )0 0.003 MGD Ex lanation: I Current permit limits per IUP Section F IUP Application—blank_apr_2012 Page 10 of 21 INDUSTRIAL USER WASTEWATER SURVEY AND DISCHARGE PERMIT APPLICATION SECTION F — CHEMICALS, POLLUTANTS, WASTES Complete Checklist for Priority, Conventional, Non -Conventional, and Other Pollutants. All chemicals reauire that TWO columns are checked Chemical Abstract Present in Absent in Concentration Number Present Absent Discharge to Discharge to in Discharge, Chemical Name CAS# at Facilit at Facility POTW POTW m /I Acid Extractable Oraanic Comoounds (EPA Method 6251 2-Chloro henol 95-57-8 X _ X 2,4-Dichlorophenoi 120-83-2 X X 2,4-Dimethylphenol 105-67-9 _ X _ X _ _ 2,4-Dinitrophenol J 51-28-5 X X 2-Methyl-4,6-dinitrophenol 534-52-1 X X 4-Chloro-3-methylphenol 59-50-7 X X 2-Nitrophenol 88-75-5 X X 4-Nitrophenol 100-02-7 X X Pentachlorophenol 87-86-5 X X Phenol 108-95-2 X X 2,4,6-Tdchiorophenol 88-06-2 X X Base Neutral Oraanic Comoounds (EPA Method 6251 1,2,4-Trichlorobenzene 120-82-1 X _ X 1,2-Dichlorobenzene 95-50-1 X X _ 1,2-Diphenylhydrazine 122-66-7 X X 1,3-Dichlorobenzene 541-73-1 X X 1,4-Dichlorobenzene 106-46-7 X X 2,4-Dinitrotoluene 121-14-2 X X 2,6-Dinitrotoluene 606-20-2 X X 2-Chloronaphthalene 91-68-7 X X 3,3-Dichlorobenzidine 91-94-1 X X 4-Bromophenyl phenyl ether 101-55-3 X X 4-Chlorophenyl phenyl ether 7005-72-3 X X Acenaphthene 83-32-9 X X Acenaphthylene 208-96-8 X X Anthracene 120-12-7 X X Benzidine 92-87-5 X X Benzo (a) anthracene 56-55-3 X X Benzo (a) pyrene 50-32-8 X X Benzo (b) fluoranthene 206-99-2 X X Benzo (ghi) perylene 191-24-2 X X Benzo (k) fluoranthene 207-08-9 X X Bis (2-chloroethoxy) methane 111-91-1 X X Bis (2-chloroethyl) ether 111-44-4 X X Bis (2-chloroisopropyl) ether 102-60-1 X X Bis (2-ethyihexyl) phthalate DEHP 117-81-7 X X Butyl benzyl phthalate [BBP] 85-68-7 X X Chrysene 218-01-9 X' X Di-n-butyl phthalate [DBP] 84-74-2 X X Di-n-octyl phthalate [DOP] 117-84-0 X X IUP Application_blank_apr_2012 Page 11 of 21 INDUSTRIAL USER WASTEWATER SURVEY AND DISCHARGE PERMIT APPLICATION SECTION F — CHEMICALS, POLLUTANTS, WASTES (continued) All rhemiralc ronniro that TWO enhqmnc ArP nheckerl Chemical I Abstract Present in Absent in I Concentration Number Present Absent I Discharge to Discharge to In Discharge, Chemical Name rCAS#jat Facilitv at Facilit POTW POTW m /I Base Neutral Organic Compounds (continued) Dibenzo (a,h) anthracene 53-70-3 X X Diethyl phthalate [DEP] 84-66-2 X X Dimethyl phthalate [DMP] 131-11-3 X X Fluoranthene 206-44-0 X X Fluorene 86-73-7 X X Hexachlorobenzene 118-74-1 X X Hexachlorobutadiene 87-68-3 X X Hexachlorocyclopentadiene 77-47-4 X X Hexachloroethane 67-72-1 X X Indeno (1,2,3-cd) pyrene 193-39-5 X X Isophorcne 78-59-1 X X N-nitroso-di-n-propylamine 621-64-7 X X N-nitrosodimethylamine 62-75-9 X X N-nitrosodiphenylamine 86-30-6 X X Naphthalene 91-20-3 X X Nitrobenzene 98-95-3 X X Phenanthrene 85-01-8 X X Pyren e 129-00-0 X X Metals Aluminum X X Antimony 7440-36-0 X X Arsenic 7440-38-2 X X Beryllium 7440-41-7 X X Cadmium 7440-43-9 X X Chromium 7440-47-3 X X Copper 7440-50-8 X X Lead 7439-92-1 X X Mercury 7439-97-6 X X Molybdenum 7439-98-7 X X Nickel 7440-02-0 X X Selenium 7782-49-2 X X Silver 7440-22-4 X X Thallium 7440-28-0 X X Zinc 7440-66-6 X X Other Inorganic Pollutants Barium 7440-39-3 X X Chloride X X Cyanide 57-12-5 X X Fluoride X X IUP Application_biank_apr_2012 Page 12 of 21 INDUSTRIAL USER WASTEWATER SURVEY AND DISCHARGE PERMIT APPLICATION SECTION E — SECTION F — CHEMICALS, POLLUTANTS, WASTES (continued) Chemical Abstract Present in Absent in Concentration Number Present Absent Discharge to Discharge to in Discharge, Chemical Name [CAS#j at Facility at Facility POTW POTW m /I 1,1,1-Trichloroethane 71-55-6 X X 1,1,2,2-Tetrachloroethane 79-34-5 X X 1,1,2-Trichloroethane 79-00-5 X X 1,1-Dichloroethane 75-34-3 X X 1,1-Dichloroethylene 75-35-4 X X 1,2-Dichloroethane 107-06-2 X X 1,2-Dichloropropane 78-87-5 X _ _ X 2-Chloroethyl vinyl ether 110-75-8 X X Acrolein 107-02-8 X X Acrylonitrile 107-13-1 X X Benzene 71-43-2 X X Bromodichloromethane 75-27-4 X X Bromoform 75-25-2 X X Bromomethane 74-83-9 X X Carbon tetrachloride 56-23-5 X X Chlorobenzene 108-90-7 X X Chloroethane 75-00-3 X _ X Chloroform 67-66-3 X X Chloromethane 74-87-3 X X Cis 1,3-Dichioropropene X X Dibromochloromethane 594-18-3 X X Ethylbenzene 100-41-4 X X Methylene chloride 75-09-2 X X Tetrachloroethylene 127-18-4 X X Toluene 108-88-3 X X Trans 1,3-Dichloropropene X X Trans-1,2-Dichloroethylene 156-60-5 X X Trichloroethylene 79-01-6 X X Trichlorofiuoromethane X X Vinyl chloride 75-01-4 X X othcr Pollutants of concern Xylene X X BOD TSS Ammonia Total Phosphorus Total Nitrogen Oil & Grease range of Ph IUP Application—blank_apr_2012 Page 13 of 21 INDUSTRIAL USER WASTEWATER SURVEY AND DISCHARGE PERMIT APPLICATION SECTION F — CHEMICALS, POLLUTANTS, WASTES (continued) 2, If any wastewater analyses have been performed on the wastewater discharge(s) from your facilities, please attach to this survey a copy of the lab report, chain of custodies and location of where the samples were taken for the most recent sampling date. Do not attach analyses performed by the POTW or analytical data already delivered to the POTW. 5. Does your facility complete a Toxic Release Inventory? [ ] Yes [X ] No If yes, most recent copy attached OR POTW already has Please list boiler and cooling tower treatment additives or M5u sneets and dosage rates Tor eacn. F ype of Boiler or Treatment Additive Name Purpose of Additive Dosage, with units ooling Unit Do you have any stora a tanks at your facilit ? Yes No If yes, com fete the chart below. Associated with L o v L o 3 [P]rocess; { > o [W]astewater o ^ m C Volume treatment; Spill (in [G]roundwater Containment Tank IDgallons) Contents remediation; Devices HD tank A I B 632 Water P Yes HD tank B I B 632 Water P Yes HD tank C I B 1700 Water P _ Yes HD tank D O B 700 _ Water P No OT Tank A I B 4500 Water P Yes 6. Are any liquid wastes or sludges (i.e. acids, alkalies, heavy metal sludges, inks, dyes, oil, grease, organic compounds, paints, pesticides, plating wastes, pretreatment sludges, solvents, thinners, waste product, etc.) from this firm disposed of by means other than discharge to the sewer system? [ X ] Yes [ ] No If ves. Dlease complete the following: Nature of Waste haulers Treatment Facility's Disposal facility's Est. Gallons or hauled name, Name, EPA ID# and Name, EPA ID# and Pounds per Waste and date EPA ID# and address Address Year hauled off Last hauled address Used Oil — Haz-Mat Haz-Mat Haz-Mat 1320 gallons 916/21 Environmental Environmental Environmental Services Services Services Borax waste — VLS Logistics — EPA VLS Environmental VLS Environmental 8000 gallons 7/6/22 ID# SCR000785186, Solutions, LLC — Solutions, LLC — 305 S Main St EPA ID# EPA ID# Mauldin, SC 29662 SCR000762468, 306 SCR000762468, 305 S Main St Mauldin, S Main St Mauldin, SC 29662 SC 29662 Is this facility a small quantity, large quantity, or conditionally exempt Hazardous Waste Generator? [ ] Small Quantity [ ] Large Quantity [ ] Conditionally Exempt [ ] Not Applicable Facility's EPA Hazardous Waste Generator ID#: Waste Codes: IUP Application_blank_apr_2012 Page 14 of 21 INDUSTRIAL USER WASTEWATER SURVEY AND DISCHARGE PERMIT APPLICATION SECTION G — WASTEWATER TREATMENT, FLOW, AND SAMPLING EQUIPMENT Is the wastewater generated by this facility treated prior to discharge to the POTW? [ X ] Yes [ ]No If yes, please complete the chart below. If a particular pretreatment unit only treats part of the wastewater, indicate this below and in the diagram required by Section B. Pretreatment Unit Yes N o Additional Information Chemicals Used Activated Carbon _ Air Stripping Biological Treatment Activated Sludge Rotating Biological Contactor (RBC) Trickling Filter Sequencing Batch Reactor (SBR) Other Chemical Precipitation Y BL 1302 - Caustic Soda 25% Chlorination, for disinfection Cyanide Destruction Defoaming Agents Dissolved Air Floatation list all individual units of DAF here (DAF) equalization pH adjustment chemical precipitation Other Flow equalization, aerated Size(gallons) Before After Pretreatment Flow equalization, Size(gallons) not aerated Before After Pretreatment Grease and Oil Removal Grease Trap, Size for employee cafeteria, Oil Water Separator kitchen, breakroom etc. Other Grease and Oil Removal Grease Trap, Size for food manufacturing Oil Water Separator process wastewater Other Grease and Oil Removal Grease Trap, Size for non-food Oil Water Separator manufacturing process Other wastewater Heat _ Reclamation/Exchange Ion Exchange (for wastewater treatment)_ Neutralization, pH adjustment Ozonation Reverse Osmosis (for wastewater treatment Septic Tank Silver Recovery _ Solids Separation, Belt Press Centrifugation Clarification, Dewatering, Clarification Cyclone Removal, etc. Filter Press Filtration Flocculation Grit Removal Microfiltration Nanofiltration Screening Sedimentation Septic Tank Ultrafiltration Other Solvent Separation 4_1 Spill protection IUP Application_blank_apr_2012 Page 15 of 21 INDUSTRIAL USER WASTEWATER SURVEY AND DISCHARGE PERMIT APPLICATION SECTION G — WASTEWATER TREATMENT, FLOW, AND SAMPLING EQUIPMENT (continued) 2. Describe wastewater flow measuring methods and/or equipment. If applicable, list the meter's current interval, flow volume, pulse frequency and reporting units: • In -line flow meter • Flow is estimated at 3,000 gallons per month 3. List procedures employed to ensure the accuracy of flow measurement method/equipment. Frequency of CleaninqL Calibration method: Calibrated by outside party_ calibration performed by: ClearWater Traininglcredentials of calibration staff: Contracted / Outside party Date of most recent calibration: 6116/22 Copy of Calibration Certificate POTW already has OR Copy attached X 4. Describe the sampling method and associated equipment utilized at the facility. Identify staff or contract lab responsible for sampling. Describe sampling technician training. Sampling Equipment/Method: Pace Analytical - YSI ProPlus pH SM4500H+B-2011 Sampling staff: Pace Analytical - Jay Qualtieri, Nick Ausburn, _ possible other alternates Training/credentials of sampling staff: Pace Analytical NC DEQ certified field parameters NC Cert # 5342 / HAZWOPER 401-Ir trained IUP Application_blank_apr_2012 Page 16 of 21 INDUSTRIAL USER WASTEWATER SURVEY AND DISCHARGE PERMIT APPLICATION SECTION H — CATEGORICAL STATUS 1. Check any products listed below that are manufactured or activities that are performed at this facility: [ ]40 CFR 467 Aluminum Forming [ J40 CFR 432 Meat Products [ ]40 CFR 427 Asbestos Manufacturing [ X ]40 CFR 433 Metal Finishing [ ]40 CFR 461 Battery Manufacturing [ ]40 CFR 464 Metal Molding & Casting [ ]40 CFR 431 Builders Paper & Board Mills [ ]40 CFR 436 Mineral Mining & Processing [ ]40 CFR 407 Canned & Preserved Fruits & Veg. [ ]40 CFR 471 Nonferrous Metal, Form & Powders [ 140 CFR 408 Canned & Preserved Seafood [ 140 CFR 421 Nonferrous Metals Manufacturing [ ]40 CFR 458 Carbon Black Manufacturing [ 140 CFR 414 OCPSF [ ]40 CFR 411 Cement Manufacturing [ 140 CFR 435 Oil & Gas Extraction [ 140 CFR 437 Centralized Waste Treatment [ ]40 CFR 440 Ore Mining & Dressing [ ]40 CFR 434 Coal Mining [ ]40 CFR 446 Paint Formulating [ 140 CFR 465 Coil Coating [ ]40 CFR 443 Paving & Roofing Materials Mfg. ( 140 CFR 468 Copper Forming [ ]40 CFR 455 Pesticide Manufacturing [ ]40 CFR 405 Dairy Products Processing [ ]40 CFR 419 Petroleum Refining [ ]40 CFR 469 Electrical, Electronics Components [ 140 CFR 439 Pharmaceutical Manufacturing [ ]40 CFR 413 Electroplating [ 140 CFR 422 Phosphate Manufacturing [ ]40 CFR 457 Explosives Manufacturing [ ]40 CFR 459 Photographic Supplies [ ]40 CFR 412 Feedlots [ ]40 CFR 463 Plastics Molding & Forming [ 140 CFR 424 Ferroalloy Manufacturing [ ]40 CFR 466 Porcelain Enameling [ 140 CFR 418 Fertilizer Manufacturing [ 140 CFR 430 Pulp, Paper, & Paperboard [ ]40 CFR 464 Foundries, Metal Mold & Casting [ 140 CFR 428 Rubber Manufacturing [ 140 CFR 426 Glass Manufacturing [ 140 CFR 417 Soap & Detergent Manufacturing [ 140 CFR 406 Grain Mills [ ]40 CFR 423 Steam Electric Power Generation [ 140 CFR 454 Gum & Wood Chemical Manufacturing [ 140 CFR 460 Hospitals [ ]40 CFR 409 Sugar Processing [ 140 CFR 447 Ink Formulating [ ]40 CFR 410 Textile Mills [ 140 CFR 415 Inorganic Chemical Manufacturing [ ]40 CFR 429 Timber Products Processing [ 140 CFR 420 Iron & Steel Manufacturing [ 140 CFR 442 Transportation Equipment Cleaning [ 140 CFR 426 Leather Tanning & Finishing [ ] OTHER If any are checked continue with Questions 2 and 3 of this Section Otherwise, check here and skip to next Section. IUP Application_blank_apr_2012 Page 17 of 21 INDUSTRIAL USER WASTEWATER SURVEY AND DISCHARGE PERMIT APPLICATION SECTION H — CATEGORICAL STATUS - continued Is there a discharge from any of the above checked categorical operations to the POTW? [ X ] Yes [ ] No If Yes, complete table. Process operation name 40 CFR, subpart, operations, etc. 40 CFR New Source Date Date initial process start-u Date(s) major than e Wire coating process 40 CFR 433 November 1996 November 1996 N/A * Date(s) of commencement of construction of any major upgrades, updates, refits, or reinstallations of the operation since the start-up date. From the above, is this facility a [ ] New Source [ X ] Existing Source [ ] Unknown Are there any "dilution" wastestreams that flow through the current/proposed monitoring point? Yes [ ] No [ X ] If Yes, ensure these wastestreams are clearly identified as such in question EA. SECTION I — SLUG/SPILL PREVENTION and WASTE MINIMIZATION Enter employees responsible for notifying the POTW in the event of a spill, bypass, pretreatment facility upset, or other unusual discharge or problem and employees authorized to close down production if needed, along with information about training and procedures. If information is formalized in a Plan of some kind, list Plan Number and page #. Notification of POTW Plan Name, Authority to close Plan Name, page # down production page # Designated Plant Manger 6 Operations Manager 7 Employee(s)_ Training of those Plant Manger 6 employees Procedures Maintenance Supervisor 6 How other staff know Training 6 when and how to contact designated individuals? Does the facility have measures, equipment, and/or plans to protect the POTW and/or sanitary sewer in the event of accidental spills, slugs, or other inappropriate discharges)? [X ] Yes [ ] No If yes, complete table. For measures that are formalized in a Plan of some kind (eg., Spill Prevention Control and Countermeasure Plan, Spill/Slug Control Plan, Toxic Organic Management Plan), list Plan Number and page #. Note: the POTW may request copies of the identified plans. Measures to protect POTW and/or sanitary sewer Plan Name and page #s, if applicable The Wire Technology facility has 4 spill control and WASTEWATER SLUG DISCHARGE response kits (stored in drums). Locations of the kits are, one in CONTROL AND PREVENTION PLAN the hard drawn department, one in the tempering department. Page 5 one in the bouncy department and one in the oil containment area. Each kit contains at least 2 bags of oil absorbent, 1 bag of oil absorbent mats and a shovel and broom. The Wire Plant also maintains approximately 500 Ibs of absorbent material in the storage warehouse in the receiving department. IUP Application_blank_apr_2012 Page 18 of 21 INDUSTRIAL USER WASTEWATER SURVEY AND DISCHARGE PERMIT APPLICATION 3. Does your company have a pollution prevention/waste minimization/recycling/reuse program established, or have had a pollution prevention or other waste minimization audit conducted? [ ] Yes [X ] No If yes, complete Table. Name of Plan/Audit Most recent copy POTW already has copy attached 4. Please check "current', 'projected" or "N/A" for all codes below relating to your facility's wastewater discharge. N/A Current Proiected Code Description [ X ] F ] [ ] W13 Improved maintenance scheduling, record keeping, or procedures [ X ] [ ] [ ] W14 Changed production schedule to minimize equipment and feedstock changeovers [ X ] [ ] [ ] W19 Other changes in operating practices (please explain) [ X ] [ ] [ ] W21 Instituted procedures to insure that materials do not stay in inventory beyond shelf life [ X ] [ ] [ ] W22 Began to test outdated material — continue to use if still effective [ X ] [ ] [ ] W23 Eliminated shelf -life requirements for stable materials [ X ] [ ] [ ] W24 Instituted better labeling procedures [ X ] [ ] [ ] W25 Instituted clearinghouse to exchange materials that would otherwise be discarded [ X ] [ ] [ ] W29 Other changes in inventory control (please explain) [ X ] [ ] [ ] W31 Improved storage or stacking procedures [ X ] [ ] [ ] W32 Improved procedures for loading, unloading and transfer operations [ ] [ X ] [ ] W33 Installed overflow alarms, and/or automatic shutoff valves [ ] [ X ] [ ] W34 Installed secondary containment [ ] [ X] [ ] W35 Installed vapor recovery systems [ X ] [ ] [ ] W36 Implemented inspections or monitoring program of potential spill or leak sources [ X ] [ ] [ ] W39 Other spill and leak prevention (please explain) [ X ] [ j [ ] W41 Increased purity of raw materials [ ] [ ] [ ] W42 Substituted raw materials [ X ] [ ] [ ] W49 Other raw materials modifications (please explain) [ X ] [ ] [ ] W51 Instituted recirculation within a process [ X ] [ ] [ ] W52 Modified equipment, layout, and/or piping [ X ] [ ] [ ] W53 Use of different process catalyst [ X ] [ ] [ ] W54 Instituted better controls on operating bulk containers to minimize discarding of empty containers [ X ] [ ] [ ] W55 Change from small volume containers to bulk containers to minimize discarding of empty containers IUP Applicabon_blank—apr_2012 Page 19 of 21 INDUSTRIAL USER WASTEWATER SURVEY AND DISCHARGE PERMIT APPLICATION N/A Current Projected Code Description [ ] [ ] [ ] W58 Other process modifications (please explain) [ ] [ ] [ ] W59 Modified stripping/cleaning equipment [ ] [ ) ( ] W60 Changed to mechanical stripping/cleaning devices (from solvents or other materials) [ ] [ ] [ ] W61 Changed to aqueous cleaners (from solvents or other materials) [ ] [ ] [ ] W62 Reduced the number of solvents used to make waste more amendable to recycling [ ) [ ] [ ] W63 Modified containment procedures for cleaning units [ J [ ] [ ] W64 Improved draining procedures [ ] [ ] [ ] W66 Modified or installed rinse systems [ ] [ ) [ ] W67 Improved rinse equipment design [ ] [ ] [ ] W68 Improved rinse equipment operation [ ] [ ] [ ] W71 Other cleaning and degreasing operation (please explain) [ ] [ ] [ ] W72 Modified spray systems or equipment [ ] [ ] [ ] W73 Substituted coating materials used [ ] ( 1 [ ] W74 Improved application techniques [ ] [ 1 [ ] W75 Changed from spray to other system [ 1 [ ] [ ] W78 Other surface preparation and finishing (please explain) [ ] [ ] [ ] W81 Changed product specifications [ ] [ ] [ ] W82 Modified design or composition of product [ ] [ ] ( ] W83 Modified packaging [ ] [ ] [ ] W89 Other product modifications (please explain) W99 Other (please explain) IUP Application_blank_apr_2012 Page 20 of 21 INDUSTRIAL USER WASTEWATER SURVEY AND DISCHARGE PERMIT APPLICATION SECTION J — OTHER PERMITS List all environmental control permits currently managed for or by this facility. Examples: air, National Pollutant Discharge Elimination System (NPDES), Industrial User Permits (IUP), Resources Conservation and Recovery Act (RCRA), groundwater, storm water, general, non -discharge, and septic tank. Be prepared to provide the POTW with copies of identified permits and related records. Permit Type Permit Number Issuing Agency Storm Water General NCG030000 Certificate of Coverage (COC) No. NCG030673 State of North Carolina Wastewater Discharge IUP# 101 HS City of Conover 2. With regard to the parent company and all subsidiaries, list all wastewater discharge permits issued to cover similar operations to those at this facility. Examples: National Pollutant Discharge Elimination System (NPDES), Industrial User Permits (IUP), groundwater, general, non -discharge, and septic tank. Be prepared to provide the POTW with copies of identified permits and related records. Facility and Location Permit Type Permit Number Issuing Agency HSM Hickory Metal Plant Industrial User Pretreatment permit NCO040797 IUP 0033 City of Hickory, NC HSM Fort Smith Significant Industrial User permit CIUP040102 City of Fort Smith, AR 3. With regard to the parent company and all subsidiaries, list all environmental permits applied for in the United States where issuance was denied OR the permit was terminated prior to the expiration date. Examples: air, NPDES, IUP, RCRA, groundwater storm water, general, non -discharge, and septic tank. Be prepared to provide the POTW with copies of identified permits and related records. Permit Type Issuing Agency Date Facility Name and Location Reason for Denial/Termination N/A IUP Application_blank_apr_2012 Page 21 of 21 Instrumentation Service ! Calibration PO Box 1469 Hickory, NC 26683 Phone (828) 855-3182 www.clearwaterinc.net d IN ji 05/16/2022 MR WIN` Hickory Springs - HSM Con over w 1115 Farrington Street ConoverWil - x• s ' 1 NC 128613 X` R t'f;�,W.j;�x •�%�. •tea _ ���',s�'�' -� ` � ��-. Tim Mathis twmathls®hsmsolutions.com --- 828.320-9766 NEW Calibration 22051609462686 n)c a b t'ec'Llptcian` o e 'x R4 O r% V i.� lam` - - .e .�<<s4 _ i ATFt'.4:.ro4seYe `A'^h`"-A mlchael.outiaw@clearwaterinc.n Michael Outlaw 704-236-0851 et Sates a� a-- "WIN" - 704-953-3565 erie.hudson(?Pclearwaterinc,net Eric Hudson Calibration Letter PO Box 1469 HWwry, NC 28883 Phone (828) 855-3182 www.cleawaterinc net CH �Ra9-Uf p�TlQ�c?+C. k -5--ems NY; Effluent Other: �K�� =cam..-•�5M r��� 31t __ `S'{i. - :'.:T13!' GPI -_ Fh...;L±� Y.{ _F Closed Pipe Y�• ONtMIN - x _"ism __ .i�Lf.> ` 34 `.SS �.�,j3' •.l'f.r `X�l�-�y' •�ae�`.%��'S�dK�'�`J���'-3 +T�h��f y+ .J ��{�rs.Y}�C�.rF �I'�'�. This Is to certify that I was at your facility to calibrate the equipment listed In this letter. A calibration sticker was placed on the equipment. If you have any questions, or if we can be of assistance In any manner, please give us a call at (828)855- 3182.