NC0001121_Approval of Request to Add New Processes_20061121

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OF V\I ATF9 Michael F. Easley
O[� OG Governor
• _v,
NCDENR William G. Ross,Jr., Secretary
> North Carolina Department of Environment and Natural Resources
Alan W. Klimek, Director
Division of Water Quality
November 21, 2006
Rodney H. Lang, EHS Engineer/ORC
Dynapar Corporation
2100 West Broad Street
Elizabethtown, North Carolina 28337
Subject: Approval of Request to Add New Processes
NPDES Permit NC0001121
Danaher Sensors and Controls
2100 West Broad Street
Bladen County
Dear Mr. Lang:
The Division of Water Quality(the Division) has reviewed your request of August 30, 2006 proposing to construct
additional gold-and silver-plating facilities. Be advised that the Division sees no reason to modify your current
permit limitations or monitoring conditions and has generated no permit change-pages.
Considering Existing Regulations—The Division concurs that proposed new metal-plating activities are consistent
with ongoing production regulated under Metal Finishing Point Source Category §40CFR,Part 433. The Division
understands that proposed new processes generate wastes compatible with current waste treatment,and that new
wastes will be treated to recover precious metals. The Division has no objections because gold is not regulated by a
water-quality standard and silver is already monitored and permit-limited to protect the receiving stream at final
Outfall 004 [see permit Effluent Limitations and Monitoring Conditions,A. (4.)].
Flow at Internal Outfall 001 —Your approved process-contact wastewater treatment system is designed to
accommodate 0.170 MGD, according to Division records. Dynapar currently averages about 0.020 MGD discharge
at this outfall(based on available data), or about 12 % of design capacity,and there is no permit flow limit at this
internal outfall. Considering that new treated wastes propose to add less than 0.004 MGD,cumulative total
discharges pose no threat to this outfall's design flow maximum.
Please notice that this permit is not transferable except after notifying the Division. The Division may modify,or
revoke and reissue this permit.This permit does not affect your legal requirements to obtain other permits required by
the Division of Water Quality,the Division of Land Resources, the Coastal Area Management Act,or other federal or
local governments.
If you have questions, or if we can be of further service,please call Joe Corporon at(919)733-5083,extension 597 or
email [e-mail].
Sincerely, •
V4,1-444-
4,_ Alan W. Klimek, P.E.
cc: Fayetteville Regional Office/Surface Water Protection Section
Central Files
Aq y Unit
N.C.Division of Water Quality/NPDES Unit Phone:[phone]
1617 Mail Service Center,Raleigh,NC 27699-1617 fax:[phone]
Internet:h2o.enr.state.nc.us DENR Customer Service Center. 1 800 623-7748

DANAHER
SENSORS & CONTROLS I \14
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2100 west Broad Street ti '� 1 tiI
Otrabethbown,NC 28337
- 0 2006 l� 1
August 29,2006
r ,hmER GOALITI
DE1R' ;unuE Icw,04
PO,.t•
Mrs. Carolyn Bryant
NC DENR/DWQ/Point Source Branch
1617 Mail Service Center
Raleigh,NC 27699-1617
Re: NPDES Application for Permit Modification
NPDES Permit No.NC0001121
Danaher Sensors&Controls
Bladen County
Dear Mrs. Bryant:
Enclosed you will find(1)original and(2)copies of a permit modification package.
This information reflects a proposed Danaher production expansion to manufacture
commutators and contacts for voltage regulators. This new production line includes a
silver-gold plating line,a nickel-gold plating line, an automatic turntable parts cleaner
and three copper grinding operations.
The only changes in our batch wastewater treatment procedures will be the addition of a
500-gallon pump tank to transfer process wastewater to the drains in the plating area.
We are not requesting any changes in our existing permit limitations. This package
includes is a copy analytical results from the process wastewater collected from acid and
alkaline basins at the Bristol site.
The timetable for this expansion is on a very tight schedule in order to maintain
continuity of production. The final decision to move was made within the last three
weeks, but we have addressed our NPDES Permit requirement as a first order of business.
We would very much appreciate your acting upon this matter as soon as possible.
Enclosed is a check for the$215 major modification fee.
Sincerely,
Rodney . Lang
EHS Engineer, ORC
910-862-5453
Enclosures

PDANAHER
SENNSORBI& CONTROLStj
Elizabethtown, NC 28337
SEP 1 3 20v°
September 12, 2006
NR-WATER QUAu�
pSOURCE 3RANCN
DE -
Mrs. Carolyn Bryant
NC DENR/DWQ/Point Source Branch
1617 Mail Service Center
Raleigh,NC 27699-1617
Re: NPDES Application for Permit Modification
Supplemental Information
NPDES Permit No.NC0001121
Danaher Sensors&Controls
Bladen County
Dear Mrs. Bryant:
Enclosed you will find supplemental analytical data for the wastewater generated by the
plating line proposed to be transferred to our facility. This process wastewater was
collected from acid and alkaline basins at the Bristol, CT site of Superior Electric.
Please do not hesitate to contact me should you have any questions.
Sincerely,
160,1"1-
Rodney H. Lang 41
EHS Engineer, ORC
910-862-5453
Enclosures

NPDES PERMIT APPLICATION - SHORT FORM C - Minor Industrial
Minor industrial, manufacturing and commercial facilitiej l�
Mail the complete application to:
N. C. Department of Environment and Natural Resgs AUG 3 0
Division of Water Quality/ NPDES Unit u
2006 '
1617 Mail Service Center, Raleigh, NC 27699-1 17
POINT SOURCE gRANCHrJ
NPDES Permit Number�IC0001121 DENR-WATER DUALITY
If you are completing this form in computer use the TAB key or the up - down arrows to move from one
field to the next. To check the boxes, click your mouse on top of the box. Otherwise,please print or type.
1. Contact Information:
Owner Name Kenneth J.Verhulst- Plant Manager
Facility Name Danaher Sensors &Controls
Mailing Address 2100 West Broad Street
City Elizabethtown
State / Zip Code North Carolina / 28337
Telephone Number [phone]
Fax Number [phone]
e-mail Address hverhulstldancon.com
2. Location of facility producing discharge:
Check here if same as above ISI
Street Address or State Road
City
State / Zip Code
County
3. Operator Information:
Name of the firm, consultant or other entity that operates the facility. (Note that this is not referring to the
Operator in Responsible Charge or ORC)
Name Dynapar Corporation
Mailing Address 2100 West Broad Street
City Elizabethtown
State / Zip Code North Carolina / 28337
Telephone Number [phone]
Fax Number [phone]
Don,4 nf S r_Iu1F warm
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NPDES PERMIT APPLICATION - SHORT FORM C - Minor Industrial
Minor industrial, manufacturing and commercial facilities.
4. Ownership Status:
Federal ❑ State 0 Private ® Public 0
5. Standard Industrial Classification (SIC) code(s): 3824
6. Number of employees: 350
7. Describe the treatment system List all installed waste treatment components with capacities,
describe the processes that generate wastewaters. If the space provided is not sufficient attach a
separate sheet of paper with the system description.
Waste Treatment - Chrome batch treatment tanks (2 each,0.0155MG), Cyanide batch
treatment tanks (2 each,0.0375MG), Wet Well (0.005MG), Clarifier (0.085MG), Sludge
Filter Press and Sludge Holding Tank(0.010MG)
Existing Plating Operation - Various metal parts are cleaned and finished either by
electroplating or dipping into aqueous solutions. The solutions include zinc cyanide,
copper cyanide, nickel sulfate, chromium, phosphate conversion, trivalent chrome
passivation, silver cyanide, alkaline cleaning, acid salts pickling, rinsing and rust
preventative. The solutions require periodic replacement or replentishment of chemical
contents. Separate drains within the plating area connect to specific wastewater
treatment tanks.
The proposed production line includes a silver-gold plating line, a nickel-gold plating
line, an automatic turntable parts cleaner and three copper grinding operations.
The plating lines have operated in Bristol, CT, but will be dismantled and re-installed
without change in our existing plating area. The volume of process wastewater resulting
from the added plating operations will be approximately 6,000 gallons per operating day,
to occur twice weekly, or 2400 gpd. The plating lines are equipped with electrolytic
recovery systems for the precious metals. Process wastewater containing cyanide rinse
will be pumped to the drain for cyanide batch treatment. Process wastewater containing
low pH rinse will be pumped to the drain for metals batch treatment.
The automatic turntable parts cleaner is an aqueous jet spray followed by a rinse cycle.
The parts cleaner filters and re-circulates a mild detergent cleaning solution. The rinse
water is diverted to not enter the cleaning solution. The rinse water (4-gpm for 4 hours
or 960 gpd) and any spent cleaning solution (200 gallon tank) will be pumped to a 500-
gallon pump tank leading to the drains in the plating area.
Two copper grinding stations use an aqueous grinding solution (water, diethanolamine,
and Emery 622 coconut fatty acid). The copper grindings are removed by filtering the
solution as it enters a common reservoir. As needed, the spent grinding solution is
pumped to a series of two solids settling tanks. The overflow enters the 500-gallon
pump tank leading to the drains in the plating area. The third copper grinding station
uses an aqueous solution (water, silicon carbide, and Elfdraw S 1205). The grinding
solution is self contained and disposed of as a non-hazardous waste. The combined
volume of the rinses for the copper grindings stations is 500 gpd and will be pumped to
the 500-gallon pump tank leading to the drains in the plating area.
Total process wastewater flow from the new production is estimated to be 2400 + 960 +
500 = 3860 gpd.
Dona 0 of F r_ut ming

NPDES PERMIT APPLICATION - SHORT FORM C - Minor Industrial
Minor industrial, manufacturing and commercial facilities.
12. Types of wastewater discharged to surace waters only
Flow
Discharge
(GALLONS PER DAY)
Sanitary - monthly average 0
Non-contact Cooling 002, etc.- 2000
monthly average
Process wastewater 001 - 23860
monthly average
Boiler, Chiller, Heat Treat, Local Storm 10000
Water to Storm Drain - monthly average
Other-monthly average
Explain: Groundwater Recovery 003 150000
Monthly Average 185860
total discharge (all types)
13. Number of separate discharge points: 4
Outfall Identification number(s) 001 -Wastewater Treatment. 002 -Non-contact Cooling.
003 -Groundwater Recovery through Air Stripping Tower.004-Combined 001. 002. 003
(Weals
14. Name of receiving streams) (Provide a map showing the exact location of each outfall, including
latitude and longitude):
Cane rear River
15. Effluent Data
Provide data for the parameters listed Temperature and pH shall be grab samples,for all other parameters 24-hour
composite sampling shall be used.If more than one analysis is reported, report daily maximum and monthly
average.If only one analysis is reported, report as daily maximum.
Daily Monthly Units of
Parameter
Maximum Average Measurement
Biochemical Oxygen Demand (BOD5)
Chemical Oxygen Demand (COD)
Total Organic Carbon
Total Suspended Solids 4 2 mg/L
Ammonia as N
Temperature (Summer) 22 20 Celsius
Pane a,f g rax AVM

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NPDES PERMIT APPLICATION - SHORT FORM C - Minor Industrial
Minor industrial, manufacturing and commercial facilities.
Temperature (Winter) 18 17 Celsius
pH 7.8 max 7.6 min Stand. Units
Fecal Coliform (If sanitary waste is
present)
Total Residual Chlorine (if chlorine is 0.01 0.01 mg/L
used)
16. List all permits,construction approvals and/or applications (check all that apply and provide permit
numbers or check none if not applicable)
Permit
Type Permit Number Type Number
Hazardous Waste (RCRA) NCD04146625 NESHAPS (CAA) none
UIC (SDWA) none Ocean Dumping(MPRSA) none
NPDES NC0001121 Dredge or fill (Section 404 or none
PSD (CAA) none Other NC0030176
Non-attainment program none
17. List any chemicals that may be discharged (Please list and explain source and potential
amounts.)
Hydraulic Oil- small potential most quantities would be captured by oil water separator on
002.
18. Is this facility located on Indian country? (check one)
Yes ❑ No ►_.4
Dane "if !`_A,11 mum

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NPDES PERMIT APPLICATION SHORT FORM C Minor Industrial
Minor industrial, manufacturing and commercial facilities.
19.Applicant Certification
I certify that I am familiar with the information contained in the application and that to the
best of my knowledge and belief such information is true, complete, and accurate.
Kenneth J.Verhulst Plant Manager
Printed name of Person‘‘...(Si ing Title
Si a re o App 'can Date 9/66
North Carolina General Statute 143-215.6 (b)(2) provides that: Any person who knowingly makes any false
statement representation, or certification in any application, record, report, plan, or other document files or
required to be maintained under Article 21 or regulations of the Environmental Management Commission
implementing that Article, or who falsifies, tampers with, or knowingly renders inaccurate any recording or
monitoring device or method required to be operated or maintained under Article 21 or regulations of the
Environmental Management Commission implementing that Article, shall be guilty of a misdemeanor
punishable by a fme not to exceed $25,000, or by imprisonment not to exceed six months, or by both. (18
U.S.C. Section 1001 provides a punishment by a fine of not more than $25,000 or imprisonment not more than
5 years, or both,for a similar offense.)
Dana arrs r..11/11 AMA
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I • mlisi.AUG. 25. 2006'. 6:25AM1 203SUPERIOR ELECTRIC CONNTESTING LABNO USS F. 1 tg3ool
a baa
�� Pagelkl1/4,fv. 9 la 0
Date Samples Received: 8/10/05
Client Name: Superior Electric CTL Lab No. : 0806172
Report Date : 8124106 PO/Job No. : NA
a LAI)
fioRESULTS OF ANALYSIS ..--/-0 0
Matrix-type t W /
CTL Sample No. 14255 14257
Field ID: Acid Alkaline
Basin Basin
Before Before
Treatment Treatment
Parameters MDL
Co er,Tonal-m /..L_____13_11._ 2.07 5.46
Nickel,Total-rng/L 0.05 9.94 0.05
Lead.Total-mq/L 0.005 0.036 BDL
Tin Total-m A. 0.5 BDL DL
Zinc,Total-mg/L __ 0-05 BDL 0.05
Matrix Type: W
CTL Sample No.. 14256
Field ID : Alkaline
Basin
Before
Treatment
Parameters MDL
C ankle Total-m•/L 0.05 0.07
MDL=Method Detection Level BDL=Below Detection Level
Matrix Types: W=Water/Aqueous 5=Soil/Solid 0=Oil/Hydrocarbon
post-it"Fax Note 7671 t)e" O - •rssl" i .
To 17) _ From _ f G,
COJDept C; ,,,'GJ 1�E�t°tC�i L--
Phenst '�f�1 ewe-,
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08-25-06 06:27 TO:DANAHER CONTROLS FROM:8605823784 P01
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